Fraunhofer Institute for Production Systems and Design Technology
Fraunhofer Institute for Production Systems and Design Technology

Handheld Laser Welding

Efficient and distortion-free joining of thin sheets

What is handheld laser welding?

Handheld laser welding, manual laser welding, is a process that is increasingly being used in industry to join thin sheets with minimal distortion. In this manual process, the operator guides a welding gun along the edge to be welded. The energy source is a laser, which is shaped by optics into a line or other defined figures. Depending on the application, a filler wire may also be used. The weld bead is protected by a shielding gas, usually argon or nitrogen, which flows parallel to the laser. 

 

How does handheld welding work?

Handheld laser welding is particularly suitable for applications that require high welding precision, minimal distortion or thin sheet thicknesses. As a manual process, it is primarily used in custom manufacturing and for small batch sizes, such as in vessel construction. The laser can be used to quickly and easily join unalloyed, low alloyed and high alloyed steels, as well as aluminum and nickel-based alloys. Titanium and copper alloys can also be processed. Typically, T-, overlap or corner joints are welded, but I-joints are also possible. The depth of penetration varies depending on the material, the joint type and process parameters, especially the maximum laser power of the machine.

Manual laser welding with or without filler wire

© Fraunhofer IPK / Raphael Marquardt
Precision in the palm of your hand: Handheld laser welding enables fine, precise welds on complex components.

Handheld laser welding vs. other processes

Handheld laser welding is characterized by a concentrated and directed energy input compared to conventional arc-based processes such as MIG, MAG and TIG. This results in a smaller heat affected zone, even with thin sheets, as well as less distortion and therefore less straightening. Also, the appearance of the welded assemblies is improved by the very high seam quality of handheld laser welding. The much simpler handling compared to arc-based processes also makes it easier to quickly train new employees in the process. Common systems also have a laser cleaning function to remove rust and dirt. Oxide layers can also be removed, which improves weld quality when welding aluminum. With handheld laser welding, operations can be simplified and operator efficiency increased.

Challenges of handheld laser welding

Handheld laser welding requires a new approach to process design. For example, seam preparation can be eliminated in certain applications if sufficient edge quality is achieved. The lower heat input at higher cooling rates can also result in different microstructures compared to arc-based processes. A deeper understanding of the laser welding process can often be used to optimize the system for specific applications. Probably the biggest challenge for SME is laser safety. Unlike conventional arc processes, lasers require properly designed safety equipment, laser-specific personal protective equipment and a laser safety officer. 

Our handheld laser welding services

© Fraunhofer IPK / Raphael Marquardt

R&D for your company

 
  1. We can help you realize the savings potential of handheld laser welding.
  2. In feasibility studies, we evaluate parameters and material combinations according to your requirements using metallographic examinations.
  3. Distortion simulation can also be used to digitally optimize the welding process strategy to avoid expensive material testing.
 

Welding Structure Simulation for handheld laser welding

  • Simulate and optimize simple and complex welded assemblies
  • Calculate thermal stress, residual stress, and weld distortion
  • Process window and fixture design
  • Virtual validation to dramatically reduce test costs
Welding Structure Simulation

Handheld laser welding

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