Common problems and solutions of handheld laser welding

1. Slag splash

In the process of laser welding, the melted material slag splash, attached to the surface of the base material, affecting the appearance of the product.

Causes of the problem: 1. too much power to melt too fast 2. the surface of the base material is not clean 3. the gas is too strong

Solution: 1. properly adjust the power 2. pay attention to the surface of the base material clean 3. reduce the gas pressure

2. The weld seam is too high

The weld seam is significantly higher than the conventional level, resulting in a fat weld seam that looks unattractive.

Cause of the problem: 1. wire feed speed is too fast 2. wire is too thick 3. power is too small

Solution: 1. Reduce the wire feed speed in the control system 2. Replace the wire with finer wire 3. Adjust the machine power appropriately

3. Welding Offset

The weld is not solidified at the structural joint, resulting in misalignment and welding failure.

Cause of the problem: The laser beam is not pointing in the right position and is not in line with the position of the wire and the weld seam.

Solution: 1. Check the connection between the wire feeder and the laser head for deviations 2. Adjust the laser offset and swing angle in the system

4. Weld seam color is too dark

Cause of the problem: 1. excessive heat buildup in the weld, resulting in high temperature oxidation 2. insufficient purity of shielding gas

Treatment: 1. adjust the Laser power, Laser frequency, Laser duty, Wobble length and Wobble frequency, so that the base material is melted through the premise, but also good heat dissipation. 2. the use of high-purity shielding gas 3. use the laser to clean the weld, or use a special cleaning solution to clean the weld

Check this to know more about Laser duty

5. Uneven corner welding formation

Inside and outside corner welding when the corner is not adjusted to speed or posture, which can easily lead to uneven welding at the corner, affecting both the strength of the weld and the beauty of the weld.

Cause of the problem: 1. not skilled in the correct welding angle and posture

Solution: 1. Use the appropriate welding nozzle 2. Beginners try to use the overall movement of the arm instead of using the wrist rotation to drive the torch movement, which can make the error tolerance rate higher

6. Weld depressions

Dents in the welded joint can lead to insufficient welding strength and unqualified products

Cause of the problem: 1. The laser energy is too concentrated 2. The laser focus is incorrectly set and the true focus is too far from the inner surface of the base material, causing the melt pool to be too deep and the material to be melted excessively, resulting in a sunken weld seam 3. The weld seam is too large

Solution 1. turn on the laser beam swing to enhance the laser beam stirring the molten pool 2. adjust the laser focus 3. use thicker welding wire

7. Uneven weld seam thickness

Weld seam is sometimes too large, sometimes too small, sometimes normal

Cause of the problem: Uneven light or wire feed

Solution: 1. Check the stability of the laser and wire feeder including power supply voltage, cooling system, ground wire, etc.


Article written by XING Laser


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