LaHDo: Laser hybrid welding for thick-walled steel

Sustainable Connections Laser Beam Hybrid Welding Saves Twice Over

2026-11-12 Source: LZH | Translated by AI 2 min Reading Time

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There is a joint project called “LaHDo”. As part of it, Laser Zentrum Hannover is developing, together with partners, a novel welding process for thick-walled components plus the matching system technology ...

Here you can see unalloyed sheet-metal components around 30 millimetres (approx. 1.2 inches) thick. They play the most important role in a research project. This is because a novel welding process called laser beam hybrid welding is to be tested on them. The Laser Centre Hanover is ...(Image: LZH) — Here you can see unalloyed sheet-metal components around 30 millimetres (approx. 1.2 inches) thick. They play the most important role in a research project. This is because a novel welding process called laser beam hybrid welding is to be tested on them. The Laser Centre Hanover is ...
(Image: LZH)

When welding thick-walled steel components, large amounts of energy and filler material have so far been required, according to the Laser Zentrum Hannover (LZH). In the project “Laser beam hybrid welding with double wire for process- and energy-efficient joining of thick-walled components” (“LaHDo”), work is therefore now being carried out on a new laser-based hybrid welding process that reduces this material requirement. In this process, the arc, with the help of two melting wire electrodes, fills the weld seam at a high deposition rate, it is further stated. An additional laser beam is moved in an oscillating motion and specifically activates the joint flanks, which ensures better bonding of the material. In contrast to conventional processes, in which the joint is filled by multiple layers of filler material, this welding innovation is intended to require only a single layer. This makes it possible to significantly reduce both energy and material requirements. For this purpose, the project partners are using thick-walled components made of unalloyed steels with material thicknesses of up to 30 millimeters (approx. 1.2 inches). These are used, among other things, in mechanical engineering, for pipelines, for turbine blades, and in shipbuilding.

Here you can see how, in the novel laser beam hybrid welding process, the twin wire is melted by an electric arc in order to create reliable weld seams with less filler material and lower energy input. An oscillating laser beam supports the process.(Image: LZH) — Here you can see how, in the novel laser beam hybrid welding process, the twin wire is melted by an electric arc in order to create reliable weld seams with less filler material and lower energy input. An oscillating laser beam supports the process.
(Image: LZH)

The Partners Involved in the Project Still Plan to do the Following:

In the project work, the partners are also setting up the entire process chain for the new laser-beam hybrid welding of thick-walled steel sheets, as we learn further. The LZH group “Machines and Controls” is developing a high-performance hybrid processing head for this. And the LZH group “Joining and Cutting of Metals” is developing the associated welding processes. Merkle Schweißanlagen-Technik GmbH is contributing an adapted welding power source. 4D Photonics GmbH is providing a process-integrated inline process control system, and Haane Welding Systems GmbH & Co. KG the demonstrator system. In addition, Durum Verschleißschutz GmbH is developing novel filler wires with diameters of up to 2,4 millimeters (approx. 0,1 inches) and properties suited to the welding task. The development work is being supported by associated industrial partners, including: B.I.G. Technology Services GmbH, Civan Lasers Europe GmbH, Laser on demand GmbH, Precitec GmbH & Co. KG, and Westfälische Drahtindustrie GmbH, as it concludes. (The project is funded as part of the applied energy research support program under the 8th Energy Research Programme from funds of the Federal Ministry for Economic Affairs and Energy (funding code: 03EN4132A)).

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Date: 08.12.2025

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