Dexterity Hand-Guided Laser Welding—New Possibilities for SMEs

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Fine weld seams, low deformation of the workpieces, less energy consumption and high precision: the advantages of hand-held laser welding are considerable.

Manual instead of machine: while laser welding used to be firmly in the hands of robots, more and more human welders are now turning to hand-held devices with laser beams—especially in medium-sized companies. Alongside the advantages, however, there are also requirements. "It's not for beginners," says Stephan Berekoven, DVS welding specialist and Head of Internal Sales at BSW-Anlagenbau GmbH in Everswinkel, Germany. According to the company, it is the "first company in Münsterland to be certified by TÜV for laser beam welding in accordance with DIN EN ISO 9601-1 521". This is a standard for the welding of steel. The addition 521 refers to manual laser welding. What was the reason for the certification? It was orders like this: "A customer from the field of autonomous vehicle technology needed a solution for complex stainless steel components (1.4301) at short notice.

With hand-guided laser welding, we were able to react quickly and flexibly—precisely, with little distortion and virtually no reworking. The process brings tangible time and cost benefits, especially for small series and even large orders. The high welding quality and low heat input have convinced us," says Stephan Berekoven. The energy of the laser beam is so concentrated and precisely directed onto the seam that particularly fine weld seams are created. However, welding with a handheld laser requires training and experience. "Our specialists have undergone intensive training, because hand-guided welding is not just about technology, but also about dexterity."

Gap Closed

Andrew Taupitz, Managing Director of Taupitz GmbH & Co KG, a sheet metal forming specialist based in Großenhain (Germany), Saxony, has a similar view: "Conventional welding processes quickly reach their limits, especially when it comes to complex component geometries and areas that are difficult to access—we recently experienced this impressively with a welded assembly made of thin stainless steel. Thanks to minimal heat input, high seam quality and the ability to react flexibly to the component situation, we were able to complete the job precisely and efficiently without any reworking. Hand-guided laser welding closes the gap between automation and manual work."

Safety First

"Hand-held laser welding is a modern and flexible method that does not replace traditional techniques such as TIG or MAG welding in many workshops, but complements them," confirms Oliver Würth, Technical Expert for Welding and Cutting at Air Liquide. The handy welding machine is super light and easy to operate, which makes it ideal for complex components such as stainless steel railings or fine sheet metal constructions. "The advantages are obvious: the weld seam is extremely precise, clean and very narrow. Of course, safety is the be-all and end-all. You always have to wear special laser safety goggles to protect your eyes." Working in a demarcated area ensures that nobody is exposed to the laser beam.

A Case for (Almost) All Materials

The Fraunhofer Institute for Production Systems and Design Technology (IPK) knows which materials can be welded with handheld lasers: "The laser can be used to join unalloyed, low-alloy and high-alloy steels as well as weldable aluminum and nickel-based alloys quickly and easily. Titanium and copper alloys can also be processed. Typically, T-, overlap or corner joints are welded, but I-joints are also possible," says a description of the process from the institute. "However, it is important that welding is embedded in a clean process development, because even a flawless surface can conceal defects. To avoid this, cross-sections and, if necessary, X-ray testing are useful. This effort is worthwhile: the right choice of parameters can achieve the highest evaluation group," emphasizes Raphael Marquardt, research associate for joining and coating technology at the IPK.

All in all, an economically attractive process, but one that requires careful preparation within the company and special training for the operators. Or as Stephan Berekoven says: "Only for professionals!"

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