Analysis of Common Misconceptions in Laser Welding

In industrial manufacturing, laser welding is a critical process whose quality directly impacts product safety and reliability. However, operators often fall into common pitfalls that compromise welding integrity, introduce safety hazards, and disrupt production. Below, we dissect ten prevalent laser welding misconceptions to help professionals mitigate risks and enhance process quality.

Misconception 1: Higher/Lower Current Is Always Better?

Issue Analysis: Current control is pivotal. Excessive current overloads the welding zone, burning through the base material and creating凹陷 (dents), weakening structural strength. Insufficient current fails to melt the filler material adequately, resulting in假焊 (cold joints) and hidden safety risks.

Best Practices: Optimize current based on material thickness and electrode/wire type. For 3mm steel plates with Φ2.5 electrodes, use 90–110A as a guideline, but always refer to the welder’s manual for brand-specific parameters.

Misconception 2: Neglecting Pre-Weld Cleaning

Issue Analysis: Oil, rust, or oxide layers act as barriers. These contaminants vaporize during welding, forming气孔 (pores) or slag inclusions that weaken焊缝 (welds).

Best Practices: Thoroughly grind surfaces to a metallic光泽 (luster) using angle grinders or wire brushes. Degrease with acetone for oil-free surfaces.

Misconception 3: Random Electrode Angles

Case Study: In flat welding, angles >80° destabilize the molten pool, causing uneven bead formation.

Proper Technique:

Flat Welding: Tilt electrodes 70°–80° backward for stable arcs and uniform heat distribution; use steady linear motion.

Vertical Welding: Maintain 60°–70° upward angles with zigzag oscillation and brief pauses at edges to prevent咬边 (undercut).

Misconception 4: Skipping Equipment Inspections

Risks: Gas leaks in shielded welding allow oxygen/nitrogen infiltration, oxidizing焊缝. Loose ground cables increase resistance, causing erratic arcs or fires.

Protocol: Daily checks for proper grounding, cable insulation, and gas cylinder pressure (for gas-shielded welding).

Misconception 5: Substandard Protective Gear

Hazards: Arc radiation causes photokeratitis; sparks burn skin; fumes lead to pneumoconiosis.

Mandatory PPE:

Auto-darkening helmets (DIN11+).

Flame-resistant suits + leather gloves.

Ventilation systems or certified respirators.

Misconception 6: Mismatched Base & Filler Materials

Critical Error: Using carbon steel electrodes on stainless steel accelerates corrosion at焊缝.

Guidelines:

Match chemical compositions (e.g., Q235 steel with E4303 electrodes).

Ensure mechanical equivalence for high-strength steels.

Misconception 7: Uncontrolled Interlayer Temperatures

Defects: Excessive heat in multi-layer welding coarsens grains and induces deformation.

Control Methods:

Monitor interlayer temps (150–250°C) with infrared thermometers.

Use skip welding to distribute heat evenly.

Misconception 8: Ignoring Post-Weld Treatment

Hidden Risks: Slag残留 (residue) promotes corrosion; residual stress causes cracks.

Procedure:

Remove slag with chipping hammers; polish with wire brushes.

Apply stress-relief annealing for critical components.

Misconception 9: Over-Reliance on Single Techniques

Limitations: Flat welding skills alone fail in overhead or pipe welding, leading to焊瘤 (overlap) or incomplete fusion.

Training: Master vertical, horizontal, and overhead welding; practice断弧焊 (whipping) and月牙形运条 (crescent weaving).

Misconception 10: Disregarding Environmental Factors

Forbidden Scenarios: Rain induces hydrogen cracks; confined spaces trap toxic fumes.

Requirements:

Maintain humidity <85%; use windbreaks for gusts >2m/s.

Keep water away from aluminum/magnesium alloys.

Huawei Laser Reminds You: Precision Welding, Excellence First! To empower industries in overcoming welding challenges, Huawei Laser recommends 1500W–3000W Intelligent Handheld Laser Welder Series, engineered for stainless steel, carbon steel, and aluminum alloys. Featuring real-time penetration monitoring and adaptive parameter adjustment, this portable system simplifies complex processes, eliminates traditional errors, and elevates productivity.

Contact Huawei Laser:

Email: huaweilaser2017@163.com | Official Website: www.huawei-laser.com

Note: This translation retains key technical terms in Chinese (with English explanations) to ensure clarity for global professionals. Always adhere to equipment manufacturer guidelines for specific operations.