Laser welding seams can be rough for several reasons. They usually relate to welding parameters, seam design, material matching, surface preparation, and equipment condition. The causes and fixes are below.
Possible causes
- Improper welding parameters. Laser power, welding speed, and focus position are not set correctly. This gives uneven temperature distribution in the weld and affects flatness.
- Poor seam design. The seam geometry, groove angle, width, and assembly gap are not designed well. Heat distribution during welding is uneven, so the seam is not flat.
- Material issues. The thermal expansion coefficient, melting temperature, and other properties of the welding materials do not match. This can also make the seam uneven.
- Incomplete surface preparation. Oil, oxide, and other impurities are not cleaned before welding. They can form porosity or inclusions during welding and affect flatness.
- Equipment problems. Low accuracy, poor spot shape, or a contaminated lens on the laser welding machine can also cause rough seams.
Solutions
- Adjust welding parameters. Set laser power, welding speed, and focus position based on material properties and seam requirements. Find the best parameter combination through tests to get a flat seam.
- Improve seam design. Design the seam geometry, groove angle, width, and assembly gap properly so heat is distributed evenly.
- Choose suitable welding materials. Select materials based on welding requirements. Make sure thermal expansion coefficient, melting temperature, and other properties match.
- Strengthen surface preparation. Clean the material surface thoroughly before welding to remove oil, oxide, and other impurities. Sanding, chemical cleaning, and other methods can be used.
- Check and maintain equipment. Regularly check the accuracy, spot shape, and lens cleanliness of the laser welding machine. Maintain and adjust it when problems appear.
- Use post-processing. If parameter adjustment and design optimization do not solve the problem, repair with post-processing. For example, sand or polish the seam to get a flatter surface.
We can machine custom nozzles, fixtures, protective lens holders, and other precision parts for laser welding machines from customer drawings, for single-piece or low-volume production.
Our custom precision component machining capability is not limited to laser welding equipment. Beyond welding nozzles, fixtures, and protective lens holders, we also machine RC car structural parts, yacht precision components, medical device parts, and non-standard parts for printing machinery, food machinery, and other equipment. Hansheng Automation works from customer drawings and production quantities to deliver single-piece or low-volume precision machining.
