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Laser welding

From automotive to aerospace – laser welding is suitable for many different areas of application. The decisive advantages of the process are the high welding speed and the low heat input.

Laser welding: what does it actually involve?

Laser welding is a joining process with a focused laser beam which is used in many industries due to its high precision. The energy for welding is generated by a high-performance laser. In robotic applications, the high-energy laser beam is usually guided by means of flexible optical fibers to the processing location. Here, the laser power is focused on a small focal spot with the aid of optics. The resulting high energy density melts the workpiece and welds the components. 

The process is suitable for materials and components that are to be welded at high speed with a narrow weld seam and low thermal distortion. As a result, laser welding is used for high-precision applications in a wide range of industries, including the automotive, aerospace and medical sectors.

KUKA offers a wide range of laser technologies

Laser technologies are used at KUKA for the laser welding, laser cutting, laser brazing and laser cladding of numerous materials.

Everything from a single source with KUKA

Perfectly equipped for cost-effective laser welding

Shorter product life cycles are becoming ever more common in the age of Industrie 4.0. Our robots and preconfigured cells are ideal for a dynamic production environment and can be both set up and retooled in a very short time.

Optimally coordinated and customized components

With the technology-specific KUKA.LaserTech application software, KUKA offers a tailored solution for robot-based laser applications. Beyond this, we offer components specially adapted to laser applications – from robots to preconfigured welding cells and on to a wide range of robot peripheral equipment.

  • Laser optics

    From welding optics to powder optics through to the welding head: we offer all components required for laser welding.

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  • Laser cutting gantry

    Thanks to its outstanding dynamics, our KUKA KR70 LP laser cutting gantry is particularly suitable for the laser cutting of complex components.
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  • Robot peripheral equipment

    Complete your manufacturing solution with the right robot peripheral equipment. Choose from numerous variants here. 
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  • KUKA.LaserTech

    With this software, the laser welding and laser cutting applications can be easily programmed and quickly implemented.

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Pinpoint precision and maximum versatility

Compared to a conventional welding process, the main advantages of the innovative laser beam welding process are as follows:

Advantages

Low unit costs

thanks to high process speeds and reduced reworking

High reliability

due to non-contact, force-free processes and a wear-free tool

Outstanding quality

due to low heat input and precise laser power control 

New material combinations

Copper-copper, copper-aluminum

High strength

due to great welding depths

Wide range of application

Versatile use of the process in your production

Welding by laser: the two most powerful processes

When welding with a laser, the shape and quality of the weld seam can be varied and thus optionally adapted to the task. The following technical processes in laser welding are widely used:

Deep penetration welding

Deep penetration welding requires very high power densities of about 1 megawatt per square centimeter. The laser beam then not only melts the metal, but vaporizes it. The vapor pressure creates a narrow vapor-filled hole called a vapor capillary or keyhole. As the laser beam advances through the workpiece, the molten metal flows around the capillary and solidifies in its trail. This produces a narrow, deep weld with a uniform structure. Deep penetration welding is distinguished by a great welding depth and fast process speed. Due to the high welding speed, the heat-affected zone is narrow and distortion is minimal.

Heat conduction welding

In heat conduction welding, the focused laser beam melts the base materials at the joining point. Solidification produces a smooth weld seam that does not usually require any finishing. This is why heat conduction welding is often used for visible seams. Due to the excellent consistency and controllability of the laser power, the process can also be used to join thin-walled components. The energy enters the workpiece by heat conduction only, which limits the welding depth.

What materials can be joined using laser welding?

A wide range of materials can be joined by laser welding. Steel and aluminum are often welded using the process. However, copper joints, copper-copper as well as copper-aluminum, which are often needed in battery production, can also be welded with the latest laser beam sources and adapted wavelengths, e.g. in the green or blue spectrum.

To protect the welding surface of the component from oxidation during laser welding, argon or helium is added as a shielding gas during the process.

Convert your production to the laser welding process

Together we will find the right concept.
Contact us now!

E-book: Welding aluminium? No problem!

Aluminium and aluminium alloys play an important role in e-mobility because of the ideal combination of lightness and strength. In welding and joining processes, aluminium has high demands on the processes used. With comprehensive process know-how and the right products, we make you fit for the technological transformation towards e-mobility. The example of the battery box shows how robots enable the production of aluminium components at the highest quality level;

Read what is important for aluminium welding in electromobility.

Download e-book

Laser cladding

KUKA provides individual solutions and all types of production technology for laser cladding

Learn more about our automation solutions for different industries