A Comprehensive Analysis of the Technical Principles, Core Components, and Application Fields of Laser Welding Equipment

 

As a core piece of equipment in advanced manufacturing technology, laser welding equipment has been deeply integrated into the modern industrial system thanks to its high-precision welding and efficient processing capabilities. This article will systematically analyze its technical principles, component composition, and application scenarios, and provide key guidance for equipment selection.

 

I. Technical Principles and Process Advantages

Laser welding works by applying a high-energy-density laser beam to the workpiece surface, causing the material to melt instantly and form a permanent connection. This technology has three core characteristics:

1. Precision control ability: The diameter of the focused spot can be precisely controlled to the micron level, enabling the welding of ultra-thin materials (0.1 mm).

2. Heat-affected zone control: The welding speed reaches the meter-per-second level, and the heat input efficiency is 50% - 70% lower than that of traditional welding, significantly reducing workpiece deformation.

3. Multi-scenario adaptability: It supports various welding modes such as spot welding, lap welding, and seal welding, and is applicable to the connection of dissimilar materials.

 

II. Technical Analysis of Core Components

1. Laser generation unit

As the core of energy output, the choice of laser directly affects the performance of the equipment. The power of mainstream water-cooled fiber lasers ranges from 500 W to 20 kW, and the photoelectric conversion efficiency can reach 35%, which is 40% more efficient than traditional CO₂ lasers. High-power models can penetrate 25 mm stainless steel plates, meeting the needs of heavy industries such as shipbuilding.

2. Optical conduction system

It consists of two major modules: the focusing lens group and the transmission fiber.

 - The focusing lens adopts a coating process, with a reflection loss rate of ≤ 0.5%.

 - The diameter of the universal transmission fiber is 300 μm - 1000 μm, and the transmission distance can reach 30 meters.

This system, combined with a five-axis linkage mechanism, enables welding along complex spatial trajectories.

3. Temperature control support system

A dual-circulation water-cooled chiller ensures that the core components are in a constant temperature environment of 22 ± 0.5 °C. It is equipped with a flow monitoring and automatic water replenishment function, increasing the continuous working time of the equipment to over 72 hours.

 

III. Equipment Types and Application Matrix

Currently, the mainstream equipment in the market follows four major technical routes:

1. Handheld and portable: Integrates a laser source below 2 kW, suitable for outdoor maintenance and small part processing.

2. Galvanometer scanning type: The welding speed reaches 200 mm/s, used for the precise welding of electronic components.

3. Robot-integrated type: The six-axis robotic arm has a repeat positioning accuracy of ± 0.02 mm, meeting the automation requirements of automobile production lines.

4. Hybrid welding system: Combines arc welding technology to break through the thickness limitation of single laser welding.

Industry application data shows that the new energy vehicle sector accounts for 38% of the market share, and the non - defective rate of welding battery modules in power batteries reaches 99.97%. In the medical device industry, the equipment can perform non - destructive welding of micron - sized instruments such as vascular stents.

 

IV. Key Indicators for Equipment Selection

The following parameters should be emphasized in the procurement decision:

1. Material compatibility: Non - ferrous metals such as aluminum alloy require a pulse modulation function.

2. Process module expansion: Whether there are reserved interfaces for welding visual monitoring and quality traceability systems.

3. Energy consumption ratio: Models with an energy consumption of less than 0.3 kW·h per meter of weld are more economical.

4. Maintenance cost: The service life of optical components should reach over 8000 hours.

 

V. Market Development Trends

In 2024, the global market scale exceeded 30 billion yuan, with the demand in the new energy field growing at an annual rate of 65%. In the next three years, intelligent sensing and digital twin technologies will be deeply integrated with laser welding, promoting a leap - forward development in the intelligent level of equipment. When selecting equipment, enterprises should focus on technological foresight and give priority to intelligent welding systems that support Internet of Things protocols to meet the production needs of the Industry 4.0 era.