"In time, an alternative to all arc welding processes"

Time is money. In welding, not only should you consider the joint itself, but also how much time the post-processing takes to finish the pieces perfectly. Handheld laser welding saves time because there is no heat-affected zone in the material. Lastek, which markets Fanuci's devices, therefore expects this technology to boom. Especially when further developments will lead to a broadening of the playing field for this technology.

Laser welding with filler materials is a special alternative to TIG arc welding processes. "Because it is fast, there is hardly any heat input and therefore the materials do not deform. No post-treatment required, and that saves the user a lot of time and money," opens Luc Driesen, manager Expert Center at Lastek. 

A second advantage that stands out more than ever today is the low energy requirements of the process. "Classic welding power sources for arc welding operate around 250 to 300 A. Handheld laser welding consumes only a fraction of that. You can just plug it into the socket next to the coffee maker, so to speak. So with much less energy consumption, you get much higher efficiency and a much better finish on the pieces."

Consequently, expectations are high for this welding technology. "Today it is actually all still in its infancy. Laser welding with filler materials already lends itself perfectly to very specific applications. Thin materials can be joined flawlessly with a minimum of welding knowledge. In addition, there are already four-in-one devices that offer users the additional option of cleaning their workpieces as well. The laser light beam can rid the workpieces of all impurities, or remove discoloration from the weld seam, which in turn saves a hefty amount of time. Potential that remains somewhat underexposed today because everyone uses it full-time for welding. But once they have tasted this, these devices will also be quasi indispensable in work preparation."

Things have been moving fast since their introduction in 2021. An express train that will not come to an immediate halt just yet. On the contrary. Lastek expects that as the technology evolves there will be more and more applications. "We think that within five years it can be an alternative to all arc welding processes," says Lastek. 

First and foremost, studies are now under way on how to automate laser welding with filler materials. "Discussions are underway to combine it with a robot," Driesen admits. "But also the technology itself will continue to grow to higher powers, bringing thick materials into the picture as well. Today variants of 1, 1.5 and 2 kW already exist. In 2023 we will introduce a 3 kW laser welding source. The unit will then have to become more compact again to be deployable on construction sites. That development, too, is already scheduled for next year. Furthermore, we are working with SGS on a way to also deliver reliable construction work with these devices."

So a bright future awaits laser welding with filler materials? "Yes, provided at least that safety is respected. Because that is a major concern. Laser welding with filler materials works in a completely different way than conventional arc welding processes. The laser light beam that creates the weld pool has a very high intensity. Safety glasses with the right filter alone are not enough; the reflection of the laser must also be shielded from anyone working nearby. Lastek therefore wanted to master all safety aspects well. A colleague spent more than a year immersing himself in this matter, precisely because it is so crucial to provide the right guidelines and materials to ensure safe operation. The same will be true for all developments within this range. For example, the portable unit that we are launching next year will have all the safety equipment needed on site. And for laser cleaning, we are providing appropriate extraction so that the vaporized materials disappear from the room. In terms of safety, there can be no compromises," concludes Driesen.