Introducing Handheld Laser Welding – LightWELD

Morgan Rushworth has joined forces with IPG Photonics to sell the LightWELD XC fibre laser Welding Machines. Partnered with Morgan Rushworth, IPG Photonics is the world leader in fibre laser technology, with revolutionary laser solutions that enable greater precision, higher productivity and more flexible production for applications across any industry.

Handheld Laser Welding Technology

The evolution of welding technology has taken a giant leap with the LightWELD, a handheld laser welder that combines precision, safety, and ease of use. Offering a revolutionary alternative to traditional welding methods, the LightWELD ensures exceptional performance for a range of industries.

Whether you’re looking for a faster, safer, and more versatile welding solution or want to learn more about the benefits of laser welding, this guide covers everything you need to know, including frequently asked questions.

Laser Pre-Cleaning

Pre-weld cleaning removes rust and other contaminants from materials and increases weld quality. This is much faster than manual cleaning and uses no chemicals or abrasives.

Laser Welding Laser

High speed, low heat input, and a small HAZ (Heat Affected Zone) makes laser welding thick, thin, reflective materials, and materials with dissimilar thickness’s far less challenging for all skill levels.

Laser Post-Cleaning

Post-weld cleaning removes heat discolouration and improves visual finishes without post-weld grinding.

LightWELD™ enables dramatically faster welding and is easier to learn and operate than MIG or TIG. LightWELD™ provides higher-quality, consistent results with minimal distortion or part deformation.

TIG welding can generate extreme heat that deforms thin materials and produces poor visual finishes. Welding copper is difficult and welding metals of dissimilar thickness’s is limited. TIG welding is a highly skilled process, and experienced TIG welders are a scarce resource.

MIG welding requires consumable wire, material pre-cleaning, and bevelled joints for full penetration of thick metals. Travel and working angles are limited, and vertical positions can be extremely challenging. MIG is a high-heat process that can cause part deformation.

LightWELD systems are easier to learn and operate and are 4X faster than TIG welding. The low heat input and extensive material and thickness capabilities increase productivity, repeatability, and improve weld quality for operators of all skill levels.


What is Handheld Laser Welding?

Handheld Laser welding uses a highly concentrated beam of light to join materials with incredible precision. Unlike traditional methods such as MIG or TIG welding, fibre laser welding minimises heat-affected zones, ensuring cleaner, stronger welds with minimal distortion. This innovative technology is perfect for intricate work, thin materials, and applications where aesthetics and strength are critical.

How does Laser Welding Work?

Fibre laser welding generates a concentrated light beam that melts the material at the weld point. This creates a strong bond with exceptional precision. Depending on the application, laser welding can be performed with or without filler material, providing flexibility for different welding tasks. The use of shielding gas further enhances the weld quality by preventing contamination.

Why Choose Handheld Laser Welding?

Handheld laser welding is transforming the industry with unmatched benefits:

  • Precision: Achieves clean, strong welds with minimal distortion.
  • Versatility: Works on various materials, including steel, stainless steel, and aluminium.
  • Speed: Processes are faster than traditional methods, improving productivity.
  • Safety: Designed for safer operation with fewer risks of spatter and heat-related injuries.
  • Aesthetic Quality: Produces visually appealing welds, often without requiring post-welding cleanup.
  • Cost-saving: While the initial machine outlay is higher than a conventional welder, it de-skills operations, easing recruitment difficulties for experienced welders.

Safety

When it comes to Laser welding, safety is of the up-most importance. Given that laser welders utilise Class 4 laser diodes, all welding should be completed in a laser-proof workspace.

Morgan Rushworth Laser Safe Enclosures can be built to suit any space due to their modular design. Simply measure your intended space, and you can build your enclosure to suit from assorted panels, including safety interlocked doors, solid panels, or windowed panels featuring laser safety glass to allow light into the enclosures for operator comfort.

For added security and flexibility, the booth can also be configured with a 2 or 4 camera CCTV system for monitoring and safety purposes, as well as adding a protective roof (imperative if the booth can be looked into from a 2nd storey floor or mezzanine etc.

As well as the protective space, PPE is vital to protect the health and well being of operators. To this extent specialist welding helmets are required that also feature Laser protection as well as laser-safe goggles to be worn underneath. Laser’s operate on a specific electromagnetic wavelength, and would cause permanent retina damage if they were to reflect back into your eyes.

For more information, check out our full blog post on Laser Welding Safety, or check out our full checklist.

Why Choose an IPG LightWELD for Laser Welding?

LightWELD stands out for its unique combination of features, making it an excellent choice for businesses upgrading their welding capabilities:

  • Safe and Easy to Use: Designed with operator safety and simplicity in mind.
  • High-Quality: IPG Laser Welders are made in Germany, with an American Laser Source -all LightWELD models are CE Marked and up to rigorous standards for safety and quality.
  • Versatile: Suitable for welding a wide range of materials, including stainless steel and aluminium.
  • Back-up and Support: Between our team of engineers, and IPG’s Coventry headquarters, here at Selmach we can offer you all of the back-up and support you could need for your laser welder.

Common Questions About Laser Welding

Are Laser Welding Machines Any Good?

Yes, laser welding machines like the LightWELD range are highly effective, delivering precision, speed, and versatility unmatched by traditional methods.

Is Laser Welding Stronger Than MIG?

Laser welding often produces stronger bonds due to deeper penetration and reduced heat-affected zones, especially in intricate or thin material applications.

What is Laser Welding?

It’s a welding process that uses concentrated light energy to join materials. Fibre laser welding is particularly valued for its precision, strength, and speed.

Where to Buy Laser Welding Machines?

You can purchase cutting-edge laser welding machines, including the LightWELD, from Selmach Machinery – trusted experts in machinery solutions.

Can You Laser Weld Aluminium?

Yes, laser welding is effective on aluminium, though it requires specific settings to accommodate aluminium’s reflective properties and thermal conductivity.

Does Laser Welding Need Gas?

Yes, shielding gases like argon, helium, or nitrogen are used to protect the weld from oxidation and ensure a clean finish.

Does Laser Welding Use Filler?

Laser welding can be performed with or without filler material, depending on the application. For example, gaps or structural reinforcement may require a filler.

Does Laser Welding Work?

Absolutely. Fibre laser welding is widely used in industries ranging from manufacturing to aerospace due to its precision and reliability.

How Good is Laser Welding?

Laser welding is exceptional for applications requiring high-quality, repeatable results with minimal distortion or clean-up.

How Much Does a Laser Welding Machine Cost?

Costs vary by machine and features. The LightWELD 1000 is competitively priced as a cost-effective option for professional-grade laser welding. Contact us for a detailed quote.


Important Considerations

Like any technology, fibre laser welding comes with its own set of considerations. While its advantages often far outweigh the downsides, it’s important to be aware of potential challenges and how to address them effectively.

Gap Tolerance

One notable challenge with fibre laser welding is its sensitivity to gaps between components. Unlike traditional MIG welding, which can accommodate and fill larger gaps, fibre laser welding demands precise and tightly fitted parts.

This means additional preparation may be required to ensure parts align perfectly before welding. While this extra step can increase prep time, proper planning and the use of precision tools can mitigate this issue, allowing you to harness the full potential of fiber laser technology.

Delicate Laser Optics

The fibre laser welding head, a key component of the system, features sensitive optics that require careful handling. These optics are more delicate than the rugged components used in traditional welding equipment, such as MIG or TIG welders.

As a result, operators need to be mindful during use and maintenance, taking care to avoid rough handling or environments that could damage the optics. With proper care and regular maintenance, these sensitive components can deliver exceptional performance and long-term reliability.

Impact on Craftsmanship

Fibre laser welding’s simplicity is both a strength and a potential concern. The technology is so advanced that even individuals with minimal welding experience can achieve high-quality welds after a short training period.

While this “deskilling” can enhance productivity and reduce training costs, it also raises concerns among traditionalists in the industry. For some professionals, the art and craftsmanship of welding – skills honed over years of practice – may feel diminished as technology takes over.

However, this democratisation of welding can be seen as an opportunity to focus skilled labour on more complex or creative tasks, while routine welding processes are handled efficiently with minimal expertise.

Enhanced Safety Measures

Safety is a critical consideration with fibre laser welding, particularly due to the risk of retinal damage from the laser beam. Unlike traditional welding, fibre laser systems require specialised safety measures, including:

  • Welding Masks: Designed to protect against the specific wavelengths of fibre lasers as well as infrared and UV radiation.
  • Enclosures: Fibre laser-specific safety enclosures are recommended to shield nearby workers from accidental exposure to the laser beam.
  • Protective Gear: Standard welding safety equipment, such as flame-retardant overalls and welding gauntlets, is also still necessary.

Investing in proper safety equipment ensures a secure working environment while fully leveraging the benefits of fibre laser welding.

Looking for a demonstration?

We’re very excited to announce the launch of our Morgan Rushworth Demonstration Vans! You can request us to come out to your workshop, and see Laser Welding for yourself. Or you can come to our Herefordshire showroom and see the machine in action there, as well as exploring our two machinery showrooms.

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    Published 7th September 2023