The Advantages of Laser Welding in Sheet Metal Fabrications

Although laser welding started in the 1960s only a few leading metal fabrication companies offer it as a service to their customers. The technology itself is well established and there are some significant benefits to having your manufacturing projects laser welded. That said, not all materials and projects can take advantage of laser welding in the same way but it should certainly be considered.

Here’s why laser welding should be seriously considered for sheet metal fabrications:

Precise & Accurate Welds

Laser welding offers unparalleled precision, essential for the intricate and detailed work often required in sheet metal fabrication. The focused laser beam allows for exact control over the weld, ensuring minimal distortion and high-quality joints.  This benefits those complex fabrication projects where critical dimensions and relative positioning are key. Small components also benefit where tight tolerances and fine details are crucial, such as in the production of medical devices or electronic components.

Lower Production Unit Costs through Speed & Efficiency

One of the standout benefits of laser welding is its speed. The high energy density of the laser beam allows for rapid welding, significantly reducing production times. This increased efficiency can translate to lower unit costs on production runs and faster turnaround times.

Many Material Types can be Laser Welded

The best metals for laser welding typically possess good thermal conductivity, low reflectivity, and have suitable melting points for the laser wavelength used. The thickness of the material does play a part in the decision making process, typically lasers weld material 5mm and below. Here are some of the best metals for laser welding:

Stainless SteelExcellent for laser welding due to its good thermal properties and low thermal conductivity.
Mild SteelLaser welding works well with various grades of carbon steel, offering strong and durable welds.
AluminiumRequires higher laser power due to its high reflectivity and thermal conductivity.
TitaniumHighly suitable for laser welding because of its low thermal conductivity and ability to form strong welds.
Nickel AlloysGood candidates for laser welding due to their excellent thermal properties and corrosion resistance.
CopperMore challenging due to its high reflectivity and thermal conductivity, but advancements in laser technology have made it more feasible.
MagnesiumLaser welding can be effective with the right parameters to control its reactivity and flammability.
Gold and SilverLaser welding offers precision and minimal thermal distortion.
laser welding machine MA1-65 at sheet metal fabrication company Coventry UK
laser welding machine with sparks flying in use by a welder at metal fabricating company specialising in complex fabrications.

Minimised Heat Distortion

The concentrated nature of the laser beam results in a smaller heat-affected zone compared to traditional welding methods. This minimises thermal distortion and reduces the risk of compromising the mechanical properties of the base material. For thin sheet metals, this characteristic is particularly advantageous, ensuring the integrity and appearance of the final product are maintained.

Enhanced Quality & Consistency through Robotic Laser Welding

Providing the production quantities are high, laser welding can be automated to become robotic laser welding. Coupling the laser welding unit with the robot facilitates continuous high-precision production This enhances repeatability and consistency.

Clean & Environmentally Friendly

Laser welding produces fewer fumes, spatter, and waste compared to traditional welding methods. The process is clean and environmentally friendly, reducing the need for extensive post-weld cleaning and minimising the overall environmental impact of the fabrication process. Universal Fabrications is reducing its carbon footprint by 30% in 2024 and this is just one of the contributors as we work towards Net Zero.

Conclusion

Incorporating laser welding into your sheet metal fabrication project can bring many advantages from enhanced precision to lower unit costs. It is not necessarily a replacement for welding methods such as TIG and MIG but it is certainly one that should be considered.

If you have a sheet metal fabrication project that could potentially benefit from laser welding get in touch and our lead engineers can work with you to talk through the options.

Call 02476 370 272 or email us at email@universalfabrications.com