The welding industry has been revolutionized by the invention of the laser welding industry as it offers unparalleled speed and versatility. A laser welding machine is being used in a range of industries such as medical, automotive, electronics, and aerospace. No doubt that this is an advanced invention, however, these machines also face issues that affect the overall performance. But worry not as in this blog, we will explore the top seven problems which you might commonly face with laser welding machines and how you can fix it.
Inconsistent Welds
One of the most common issues faced with laser welding machines is the inconsistent welds. These irregularities can be weak welds or incomplete fusion, which can compromise the appearance and strength of the weld. This inconsistency can be caused by incorrect beam focus, variation in material thickness, poor alignment, or incorrect welding.
To fix this issue, you need to ensure that there is proper beam focus and alignment before starting the welding process. In addition, regularly calibrate the machine to maintain consistent power output. You also need to adjust the welding parameters as per the material type and thickness. Lastly, keep the welding surface free from contaminants like rust, dirt, and oil along with keeping it clean.
Overheating of the Laser Source
To create intense heat, laser welding machines rely on high-powered laser beams. If in any case, the laser source overheats, it can damage components, reduce efficiency, and can cause complete failure of the machine. As per laser welding machine manufacturers, the causes of this issue are because of malfunctioning or insufficient cooling, restricted or blocked air flow, or continuous use of machines at high power.
To fix this issue, you can go for regular inspection of the cooling system of the machine, along with monitoring the machine’s operating parameters, and ensuring proper airflow and ventilation around the laser components to prevent overheat.
Laser Spot Size Variability
The quality of the weld is greatly influenced by the size of the laser spot. If the laser spot is too small, the weld might go weak, on the other hand, if the laser spot is too large, then the weld may be too deep. This could lead to excessive heat as well. This issue can be caused by miscalibration or misalignment, dirt or contamination, and other mechanics issues like loose lenses or mirrors.
To fix this issue, it is important to go for regular maintenance of the optical system, including mirrors and lenses, by ensuring proper alignment by calibrating the optical system, or by replacing any damaged or worn components in the optical path.
Lack of Penetration
When the weld is not fully penetrating the material, it is known as lack of penetration. This issue can weaken the weld joints and can result in a poor bond between the welding materials. As per laser welding machine manufacturers, lack of penetration is caused by insufficient laser power, incorrect laser focus, too high welding speed, or inconsistent material thickness.
To fix this issue, you need to increase the laser power to ensure proper heat input for right penetration. In addition, you also need to slow down the welding speed to allow more time to heat the material. Along with this, adjust the laser focus to accommodate the difference in material profiles.
System Instability
Vibrations and system instability in the laser welding system can lead to poor-quality welds. This is because laser beams become misaligned with the workpiece. Not only this, it can also lead to inconsistent results, major damage to the machine, and misplacement of welds. This issue is caused by the machine's misalignment, worn components, unstable working environment, or lower machine foundation.
As per laser welding machine manufacturer, this issue can be fixed by ensuring that the machine is installed on a stable and vibration free surface. You also need to check and calibrate the alignment of the system, especially the mirror and the laser head to ensure that the beam remains stable and focused during the weld. Apart from this, go for regular inspection to check if the machine has any worn components.
Apart from the above-mentioned points, material loss, excessive spatter, power supply problems, and electrical issues are some problems which are faced by the owners of the laser welding machine. In all these situations, one thing that becomes important is to contact the best laser welding machine manufacturer, like CES Laser Machine Private Limited. Always remember that regular maintenance, monitoring, and cleanliness of the machine is important for the smooth functioning of laser welding machines.
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