Laser welders are continually evolving. There are handheld and portable options that produce high-quality and durable welds. Handheld laser welders are flexible and can be used in various locations because of their size. These laser welders are about 5 times faster than traditional methods. Additionally, they provide more autonomy over the laser beam welding process.
There are now many brands and sizes of handheld laser welders with different specifications and applications. As a seasoned welder or a DIY enthusiast, how then do you make the right choice? This article will walk you through various factors to consider before buying a handheld laser welder. We will start from the basics to explain what handheld lasers are so you have a core understanding of how they work and when to use them. Read on for more.
What is a Handheld Laser Welder
A handheld laser welder is an advanced and versatile device that joins parts together using a beam of light. The laser beam is generated using a solid state, gas, or fiber laser system. A laser welder assesses the workpiece from one side and focuses the energy on a small area to melt it. The molten material mixes, cool and solidly to create a strong weld. A handheld laser welder is a fast, lightweight, and versatile tool. It is compatible with various materials including metals and plastics.
How to Use a Handheld Laser Welder
Laser welding using a handheld tool involves a series of steps. Follow the simple steps below to get high-quality welds.
Preparation
- The first step is to prepare the laser welder and the workpiece. Check if the nozzle and other parts of the handheld laser welder are in good condition before welding.
- Additionally, clean the surface of the workpiece to remove contaminants that can interfere with the welding process.
Note: For large workpieces, it is important to use various clamping mechanisms to prevent unnecessary vibrations.
Set up the Laser Welder
- The next step is to generate the laser beam and focus it to a smaller spot size.
- Thereafter, select appropriate welding parameters such as pulse duration, laser power, beam diameter, and speed.
Note: Consider factors such as the material type and thickness when adjusting the parameters.
Begin Welding
- Hold the laser welder at an appropriate distance and angle from the workpiece.
- Start welding at a constant speed and motion.
Cool and Inspect
- Allow the weld pool to cool and solidify slowly.
- Thereafter, inspect the final handheld laser weld for quality and make adjustments if necessary.
Factors to Consider When Choosing a Handheld Laser Welder
There are different types of handheld laser welders available in various sizes and specifications. There is no standard way of choosing the best but there are some factors you should consider. When selecting a handheld laser welder, keep the following factors in mind.
Power
The power of the laser welder is a very important factor to consider. The laser power varies and can be as low as milliwatts to as high as kilowatts. This power output depends on the workpiece thickness and desired weld quality.
When working with metals that have low heat and electrical conductivity, the laser power may be higher. On the other hand, you may need just a few watts of power for thin metals that readily conduct electricity and heat. Hence, it is necessary to determine the power output required for your project and go for one that meets your needs.
Speed
Speed is essential in laser welding. It determines how quickly you can weld a workpiece. The speed of various handheld laser welders varies considerably and most times depends on the laser power.
If time is a determining factor, you should go for a handheld laser that gives accurate and fast results. However, the time the laser beam interacts with the workpiece will be shorter and may affect weld quality.
Material Compatibility
The material compatibility properties of the different types of handheld laser welders differ. It largely depends on the type of laser source the welder uses. Fiber, CO2, and YAG lasers are the most common you will find.
Fiber laser welders have a high power and are compatible with aluminum, brass, and copper. YAG lasers are the best for highly reflective metals like stainless steel and titanium. Furthermore, CO2 lasers are an excellent choice for different types of plastics.
Cost
Your budget is a major determining factor when it comes to selecting a handheld laser welder. The initial investment differs and depends mainly on the brand. Note that the laser welder with the lowest upfront cost may not be the most economical.
You should also consider the operating costs, how frequently you need to replace consumables, and the cost of maintenance. However, don’t be carried away with cheap prices. There should be a cost-quality balance for you to get a good return on investment.
Additional Features
Check if the laser welder has additional beneficial features. Some are equipped with safety features while others are not. Prioritize a laser welder that comes with an emergency shutdown system if a problem is detected. This type shuts down automatically in cases of malfunctioning.
Furthermore, check if the laser welder can limit laser power. This will help prevent overheat and damage to the workpiece.
Ergonomics
Handheld laser welders with ergonomic designs are easier to use and handle. It should have a comfortable grip to reduce fatigue and make welding easier. The laser welder should allow you to work at comfortable positions to improve productivity. Furthermore, using it should not cause strains to the eyes, back, and other body parts.
Maintenance Requirements
Though all handheld laser welders need regular maintenance, their requirements differ. Consider the maintenance interval specified in the manuals. You may go for the types that their parts are accessible and easy to clean. Additionally, check if spare parts are readily available.
Brand and Reputation
The brand you are going for is also an important consideration. You can ask for referrals and check the reviews of past and existing customers. Confirm if the company has industry awards and is ISO certified. It is better to go for a brand that offers a warranty under specified conditions. The company should also provide after-sales support that provides answers and solutions 24/7.
What industries use Handheld Laser Welders
Many manufacturing industries use handheld laser welders because they produce less heat and are easy to handle. The following are the most common applications of handheld laser welders
Construction and Metalworking
Handheld laser welders lead to a small heat-affected zone which makes them suitable for sheet metal fabrications. They are preferred over the use of rivets because they produce permanent connections and lightweight components. These welders are useful when constructing heavy machines and equipment. You can also use them for repair works on bridges and cranes.
Automotive Industry
Handheld laser welders are used extensively in the automotive industry for both manufacturing and repair works. You can use it to weld various components including engine parts, suspension systems, and fuel injectors. It also has applications in auto body assembly. Handheld laser welders create strong welds and ensure optimal vehicle performance.
Jewelry Manufacturing
The use of handheld laser welders is nothing new in jewelry manufacturing. It joins precious metals together such as gold, silver, and bronze without damaging the base materials. The final weld is durable and does not break down under force or impact.
Medical Industry
Handheld laser welders create clean welds that are ideal in the medical sector. The weld beads are small and strong which ensures that medical devices meet tight tolerances and specifications. You can use it to create and repair medical devices and surgical tools. Furthermore, handheld laser welders also have applications in manufacturing implants, prosthetics, and dental tools.
Tool and Die Making
Handheld laser welders are used to manufacture cutting and shaping tools in modern industries. They are compatible with many metals such as high-speed steel and tungsten carbide used in this niche. You can also use it to manufacture work holding jigs and fixtures.
Conclusion
This article has explained the many factors you have to consider before choosing a handheld laser welder for your project. After narrowing down your options, research the available manufacturers and check for track records and reviews. You then do a cost analysis to see if it fits into your budget. At this stage, if you are still unsure about the handheld laser welder to go for, consider talking to an industry expert and make use of their wealth of knowledge.