The Basics for Mastering Laser Welding Aluminum

Here you will find the knowledge and skills required for laser welding aluminum and some considerations when combined with practice.  Laser welding aluminum has many advantages over conventional welding, including a small heat-affected area, a strong weld and a smooth, aesthetically pleasing weld.

Aluminium has many applications and can be used in several industries, such as electrical equipment, chemical components, and window and door frames.

However, aluminum is a highly reflective and active metal prone to defects such as inclusions, porosity, and thermal cracking after welding.

Types of laser sources for welding aluminium

CO2 laser source

The CO2 laser source features an output wavelength of 10.6 μm and is commonly used for welding aluminum, but it is unsuitable for welding pure aluminum.

Because aluminum has high thermal conductivity and coefficient of thermal expansion, the CO2 laser source is highly susceptible to distortion during welding. If a CO2 laser source is used for welding pure aluminum, appropriate preheating and cooling measures need to be taken to ensure the quality of the weld seam.

YAG lasers

The YAG (Yttrium Aluminium Garnet) laser source uses a YAG crystal as the laser medium and has an output wavelength of approximately 1.06 μm. It produces a higher beam quality and a smaller spot size so that a higher degree of precision and control can be achieved when welding aluminum.

The YAG laser source is more suitable for welding aluminum. If you want to weld pure aluminum or aluminum alloys, use a supplementary welding material or choose pulsed laser welding, which can achieve better welding quality.

Fiber Laser

Fiber laser welder is a new technology for welding metal materials. It has an output wavelength of 1064nm and is ideally suited to welding high-quality welds. It is the most suitable laser source for welding aluminum alloys, pure aluminum and aluminum materials.

The reflectivity of aluminum to three types of laser

The CO2 laser source has a reflectivity of up to 98% and can not weld pure aluminum.

Application of laser welding aluminum

Laser welding aluminum is an emerging technology that is receiving much attention. Welding structural frames for aircraft, high-speed railways and ships use laser welder aluminum technology.

In the transport industry: aluminum is light and strong, so it is used to manufacture engines, chassis, and wings for cars and aircraft. The laser welding of aluminum makes it possible to carry out many complex welding tasks with greater precision.

Electronic machinery: circuit board chips are now used in smartphones, tablets, laptops, and other electronic products. Factories often use handheld laser welding machines to weld the electrical components on the top side of PCBs. It enables more precise and complex welding in smaller, delicate electronic components.

Industrial manufacturing: door frames, window frames, and many other metal parts and machines require aluminum as a joining component, so laser welding aluminum technology, which offers high precision and efficiency, is the preferred choice. Aluminum laser welding technology also uses for aluminum kettles, pots, pans, etc.

Renewable energy industry: Aluminium is the main material for many solar and wind power supply systems. Whether it is the production of solar panels or turbines for wind power generation, aluminum is required.

These are just a few of the common applications for laser welding aluminum. The accuracy and strength offered by laser welding aluminum make it the preferred choice for welding aluminum.

Advantages of laser welding aluminum

Laser welding aluminum has many advantages and limitations compared to conventional fusion welding.

1.Laser weld aluminum produces aesthetically pleasing and robust welds compared to conventional fusion welding.

2.Fast and productive welding of small and micro workpieces

3.Small heat-affected area and narrow weld width

4.Laser welding of aluminum is less prone to defects such as impurities and thermal cracks.

5.The small size of the laser light plate allows for a wide range of high-precision welding.