Laser welding: The future of industrial manufacturing

An Emerging Trend in the World of Joining Technology Laser Welding Experiences a Justified Upswing

2025-08-18 Source: Robert Bernhard / Civan Lasers | Translated by AI 5 min Reading Time

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There are many ways to join metal components. Just think of traditional welding. However, at Civan Lasers, they are well aware of the advantages that laser welding brings to the table.

The experts at Civan Lasers are confident that laser welding has a bright future when compared to conventional arc welding methods. Here, the laser specialists explain in detail why this is the case...(Image: Civan Lasers) — The experts at Civan Lasers are confident that laser welding has a bright future when compared to conventional arc welding methods. Here, the laser specialists explain in detail why this is the case...
(Image: Civan Lasers)

Laser welding represents one of the most important alternatives to conventional arc-based welding methods, such as metal inert gas welding (MIG), to meet the challenges of ever-increasing efficiency and sustainability demands. By utilizing advanced beam shaping technology, laser welding offers superior precision, higher processing speeds, and a more sustainable joining process. The following describes how this cutting-edge technology is transforming the welding landscape and driving the future of industrial manufacturing.

Conventional Welding Methods Have Their Certain Disadvantages

For over 100 years, conventional welding processes—such as MIG welding and submerged arc welding—have dominated the metalworking industry when it comes to joining. While these processes are reliable and proven in the field of thick sheet metal, they also have some significant disadvantages. Arc welding processes are relatively slow, often requiring multiple weld layers and passes with waiting times, subsequent cleaning, and inspection. The high and diffuse heat input, which affects the mechanical properties of the welded part and causes deformations, also necessitates temperature monitoring and robust clamping devices. Additionally, these processes are not resource-efficient as they are highly energy-intensive and have a high consumption of filler materials. Not to be overlooked is the considerable development of welding fumes, which poses risks to both personnel and the environment.

Gallery

Examples of various laser beam shapes used in welding applications. These demonstrate how optimizing energy distribution can produce excellent weld seams.(Image: Civan Lasers)

With the "Shape Generator" software, laser users can design and implement new beam shapes. This is done entirely digitally, without the need for additional optical or mechanical components.(Image: Civan Lasers)

An example of laser welding application. Here, the laser joins thick ship panels, offering advantages such as high welding speed, lower power consumption, and minimized smoke generation compared to other methods.(Image: Civan Lasers)

Welding 20-millimeter thick steel with a laser takes less than two minutes. However, with arc welding processes, it takes several hours, requiring double-sided accessibility and the execution of ten welding layers.(Image: Civan Lasers)

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Laser Welding Scores in New Application Areas

One of the emerging alternative technologies with the potential to replace conventional welding processes is laser welding. Over the past decades, lasers have primarily been used for cutting applications and have become the dominant technology for cutting thin sheets. Although laser welding has been used for over 20 years, it has so far been mainly limited to thin components, such as those typically found in the automotive industry. However, the market for electric vehicles has opened up new possibilities and introduced applications with new material combinations—such as welding copper parts for battery packs and even joining dissimilar materials like aluminum with copper, which connect battery modules with battery packs. Despite these advancements, laser welding remains a relatively small segment of the welding technology market due to various challenges.

Beam Shaping Makes Laser Welding Even More Attractive

Laser welding is a complex process in which a great amount of energy is concentrated on a very small area, typically ranging from a few hundred micrometers to one or two millimeters. The rapid heating brings the metal to its melting point—sometimes even to the point of vaporization. As the laser moves quickly across the workpiece, the melt cools rapidly, and the metal solidifies again, transitioning through phases from gaseous to liquid to solid. This rapid process can lead to various defects such as cracks, cavities, or porosities in the weld seam, which can compromise the stability of the joint. However, advancements in laser technology—particularly with fiber lasers—have increased laser power to several tens of kilowatts. This opens up new possibilities in terms of achievable speed and material thickness. Another promising advancement for laser welding is beam shaping, which has a direct impact on the melting process. New technical approaches allow the laser beam to be shaped in the focal plane, enabling control over power distribution and the characteristics of the molten pool. This ability to shape the beam affects the welding process and influences aspects such as the geometry of the weld seam, the dynamics of the molten material, and the cooling rate, thereby expanding the range of applications.

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