How Thick Can a Handheld Laser Welder Weld? Key Factors to Know

Handheld laser welders are revolutionizing the welding industry with their precision and versatility. But how thick can they actually weld? This article dives into the key factors that affect the thickness of materials a handheld laser welder can handle, offering valuable insights from Kirin Laser’s perspective.

Handheld laser welders can typically weld stainless steel up to 8-10mm thick and aluminum up to 6mm thick, depending on laser power and welding technique. Factors such as material type, power output, and welding methods play a significant role in determining the maximum thickness achievable.

To fully understand the capabilities of handheld laser welders, we need to explore several key factors that influence weld thickness. These include the material type, welding technique, power settings, and wire choice. Let’s break them down.

What material can be laser welded?

When it comes to laser welding, not all materials are created equal. Some materials are easier to weld with lasers, while others require more specialized equipment or techniques. So, what materials are best suited for laser welding?

Materials like stainless steel, aluminum, and titanium are commonly welded with lasers due to their conductive properties. However, other factors, such as material thickness and the type of laser, also play a role in the success of the weld.

Laser welding is highly effective for a variety of materials, thanks to its precision and adaptability. Understanding which materials are best suited for laser welding helps ensure a successful outcome, especially when considering the maximum thickness a handheld laser welder can handle.

Stainless Steel

Stainless steel is one of the most commonly welded materials with lasers. Its high melting point and excellent thermal conductivity make it a strong candidate for laser welding. Handheld laser welders can weld stainless steel up to 10mm thick, depending on the laser power and welding technique.

Stainless steel comes in various grades, such as 304, 316, and 410, and each has unique characteristics. For example, 316 stainless steel has a higher resistance to corrosion and is ideal for food processing and medical applications, while 304 stainless steel is commonly used in architecture and industrial sectors.

Stainless Steel1 Grade	Max Thickness (Laser Welding)	Common Applications
304	Up to 10mm	Architecture, industrial applications
316	Up to 10mm	Medical, food processing
410	Up to 8mm	Automotive, manufacturing

In general, stainless steel’s ability to absorb heat without warping makes it ideal for high-precision welding. The laser beam can focus on a specific area, reducing heat affected zones and maintaining the strength and integrity of the material.

Aluminum

Aluminum is a popular material for laser welding, though it presents unique challenges. Aluminum² has a lower melting point and higher thermal conductivity than steel, which can lead to heat dissipation and difficulty in achieving a strong weld. Handheld laser welders can typically weld aluminum up to 6mm thick.

A critical factor when welding aluminum is controlling the heat. If the heat input is too high, the material may warp or develop cracks. This is why lower-powered lasers or higher welding speeds are often used for aluminum to prevent overheating.

Material	Max Thickness (Laser Welding)	Key Considerations
Aluminum	Up to 6mm	Heat dissipation, speed control
Stainless Steel	Up to 10mm	Heat control, minimal distortion

Titanium and Other Alloys

Titanium³ is a challenging yet highly sought-after material in industries like aerospace, medical devices, and high-performance manufacturing. Handheld laser welders can weld titanium up to a thickness of 6mm, and it is often used in medical implants, as its biocompatibility is unmatched.

Titanium’s low thermal conductivity means that the material heats up quickly and retains heat, which can lead to distortion if not carefully controlled. Laser welding offers a precise solution to this issue, allowing for clean, strong welds without excessive heat buildup.

What welding wire can be chosen?

Choosing the right welding wire is just as important as selecting the right material. The type of welding wire you use can affect the quality and strength of the weld, as well as the overall process. So, which welding wires should you choose for optimal results with a handheld laser welder?

For laser welding, filler wires are typically selected based on the material being welded. Stainless steel wire is commonly used for stainless steel welding, while aluminum or titanium wires are chosen for their respective metals. The wire composition and diameter also play a role in achieving a high-quality weld.

Selecting the appropriate welding wire is crucial for ensuring the quality and durability of your laser welds. Different materials and welding requirements demand specific wire types, diameters, and compositions. Let’s explore the most common options used in laser welding.

Stainless Steel Wire⁴

When welding stainless steel, the filler wire must be compatible with the base material to ensure proper fusion. Stainless steel wires are available in different grades, including 308L, 316L, and 309L. For most applications, 308L is the most commonly used because of its balance of strength and corrosion resistance.

Wire Type	Material Compatibility	Common Applications	Max Thickness
308L	Stainless Steel	General welding of stainless steel	Up to 10mm
316L	Stainless Steel	Corrosion-resistant welding	Up to 10mm
309L	Stainless Steel	Dissimilar metal welding	Up to 8mm

The wire diameter also matters. A larger diameter is suitable for thicker materials, but it may lead to more spatter if not properly controlled. On the other hand, a smaller diameter wire is ideal for thin materials and produces finer, cleaner welds.

Aluminum Wire⁵

Aluminum wire is used when welding aluminum materials, and it comes in different alloys like 4043 and 5356. The right choice of wire depends on the aluminum alloy being welded. For instance, 4043 is commonly used for general-purpose aluminum welding, while 5356 is preferred for high-strength aluminum welding in critical applications.

Wire Type	Material Compatibility	Common Applications	Max Thickness
4043	Aluminum	General aluminum welding	Up to 6mm
5356	Aluminum	High-strength aluminum welding	Up to 6mm

The choice of aluminum wire also depends on the presence of certain alloys and their resistance to corrosion, which can affect the strength and durability of the weld.

Titanium Wire⁶

For titanium welding, titanium wire is essential. Titanium is sensitive to impurities, so pure titanium wire is used for medical and aerospace applications to prevent contamination. The most common grade for laser welding is Grade 2 titanium, which offers a balance between strength and corrosion resistance.

What should be the weld thickness?

The thickness of the weld is an essential consideration in laser welding, as it impacts both the strength of the joint and the overall appearance of the weld. How thick should the weld be, and what factors influence the maximum thickness achievable by handheld laser welders?

Handheld laser welders can typically weld stainless steel up to 8-10mm thick, and aluminum up to 6mm. The ideal weld thickness depends on factors like the laser power, welding technique, and material type. Thicker materials may require additional passes or higher power settings to achieve a successful weld.

The thickness of the weld is influenced by various factors such as material type, laser power⁷, and welding method. In laser welding, the weld thickness is crucial for determining the strength and durability of the final product. Handheld lasers are designed to handle moderate thicknesses, but thicker materials may require adjustments in welding parameters.

Laser Power

The power of the laser directly impacts the depth of penetration, which determines how thick the material can be welded. Higher-powered lasers are capable of welding thicker materials, while lower-powered lasers are limited to thinner sections. For example, handheld laser welders typically handle stainless steel up to 10mm and aluminum up to 6mm due to power constraints.

Laser Power	Material Thickness (Max)	Application Example
1000W	Up to 6mm	Thin metals, small parts
2000W	Up to 10mm	Industrial manufacturing
3000W	Up to 12mm	Heavy-duty welding

A laser power of 2000W is often used for general applications, while 3000W lasers are reserved for heavy-duty welding.

Welding Technique

The welding technique⁸ employed also plays a role in determining the weld thickness. Conduction welding, which is commonly used for thin materials, relies on the heat conducted from the laser to melt the material. On the other hand, penetration welding is used for thicker materials and involves the laser beam penetrating deeper into the material to create a more robust bond.

Technique	Best For	Max Material Thickness
Conduction Welding	Thin materials	Up to 6mm
Penetration Welding	Thick materials	Up to 10mm

Material Properties

The material being welded affects how thick the weld can be. Stainless steel and aluminum have different thermal properties, which impact how heat is absorbed during welding. For example, aluminum requires more heat to weld compared to steel, but it also tends to dissipate heat faster, limiting its weld thickness⁹.

What are the tolerances for laser welding?

Laser welding is known for its precision, but what kind of tolerances can be expected? Understanding the tolerances for laser welding is crucial for industries that demand high-quality, accurate welds. Let’s look at what tolerances are achievable with handheld laser welders.

Laser welding offers tight tolerances, with typical ranges of ±0.1mm to ±0.5mm depending on the machine and settings. For critical applications, such as aerospace and medical devices, even tighter tolerances may be necessary, and advanced laser machines can achieve this level of precision.

Tolerances are a critical aspect of laser welding, especially in industries that demand high accuracy and precision. The ability to achieve tight tolerances¹⁰ is one of the key benefits of laser welding, making it ideal for applications where precision is paramount.

Precision of Handheld Lasers

Handheld laser welders offer excellent precision compared to traditional welding methods. The beam of the laser is highly focused, allowing for clean and accurate welds with minimal distortion. As a result, tolerances of around ±0.1mm to ±0.5mm are common in most laser welding applications. For more critical applications, such as aerospace or medical industries, even tighter tolerances can be achieved with advanced machines.

Tolerance Range	Common Use Case	Application Example
±0.1mm	High-precision welding	Aerospace, medical
±0.5mm	General industrial use	Automotive, manufacturing

Factors Affecting Tolerances

Several factors influence the final tolerances in laser welding. These include the power settings, welding speed, material type, and the thickness of the weld. Additionally, the operator’s skill and experience play a significant role in ensuring that tolerances are met consistently. In general, handheld laser welders can provide reliable tolerances, but achieving the highest precision requires fine-tuning the welding parameters.

Conclusion

Handheld laser welders¹¹ are a powerful tool in the welding industry, offering high precision and versatility. While the thickness they can weld is influenced by factors like material type, laser power, and welding technique, these machines can handle a variety of tasks. Whether you’re welding stainless steel, aluminum, or titanium, understanding the key factors like welding wire, material properties, and tolerances will help you make the most of your handheld laser welder for efficient and high-quality welds.