Fiber laser welding machines are widely used in various industries for precision welding, including wires welding. Here's an overview of how they work and their application in wire welding:
How Fiber Laser Welding Machines Work
Laser Generation:
A fiber laser generates a high-intensity beam (typically 1,060 nm wavelength) using doped optical fibers as the gain medium.
The laser beam is delivered through a flexible fiber optic cable, allowing precise control.
Beam Focusing:
The laser beam is focused onto the workpiece using a lens or scanning mirror system, creating a tiny, high-energy spot (as small as 0.1 mm).
High power density (up to several MW/cm²) enables deep penetration welding with minimal heat input.
Welding Process:
The laser beam melts the material at the joint, forming a weld pool.
Shielding gas (e.g., Argon or Nitrogen) is often used to prevent oxidation.
The process can be automated with CNC or robotic systems for high precision.
Wire Welding Applications
Fiber laser welding is ideal for welding thin wires (copper, aluminum, steel, etc.) in industries like electronics, automotive, and medical devices. Common applications include:
Battery welding (Li-ion battery tabs, terminals)
Sensor & microelectronics (fine wire connections)
Medical devices (pacemaker leads, surgical tools)
Automotive wiring harnesses
Advantages for Wire Welding
✔ High Precision – Can weld wires as thin as 0.01 mm without damaging adjacent areas.
✔ Speed – Faster than TIG or resistance welding (up to meters per second).
✔ Low Heat Input – Reduces thermal distortion, crucial for delicate components.
✔ No Contact Required – Non-contact process minimizes wire deformation.
✔ Automation-Friendly – Easily integrated into robotic systems.
Challenges in Wire Welding
Reflective Materials (e.g., copper, aluminum) may require higher power or green lasers (515 nm).
Alignment Precision – Small wires require accurate fixturing.
Joint Fit-Up – Gaps must be minimal for consistent welds.
