Laser Beam Welding

Laser Beam Welding is a fusion welding process in which two

metal pieces are joined together by the use of laser. The laser
beams are focused to the cavity between the two metal pieces to
be joined. The laser beams have enough energy and when it
strikes the metal pieces produce heat that melts the material from
the two metal pieces and fills the cavity. After cooling a strong
weld is formed between the two pieces.It is a very efficient welding
process and can be automated with robotics machinery easily.
This welding technique is mostly used in the automotive industry.
Working Principle
It works on the principle that when electrons of an atom gets

excited by absorbing some energy. And then after some time

when it returns back to its ground state, it emits a photon of light.

The concentration of this emitted photon increased by stimulated

emission of radiation and we get a high energy concentrated laser

beam.Light amplification by stimulated emission of radiation is

called laser. The main parts or equipment of laser beam welding are:

1. Laser Machine: It is a machine that is used to produce a

laser for welding. The main components of the laser
machine are shown below.
2. Power Source: A high voltage power source is applied
across the laser machine to produce a laser beam.
 4.CAM: It is a computer-aided manufacturing in which the
laser machine is integrated with the computers to perform
the welding process. All the controlling action during the
welding process by laser is done by CAM. It speeds up the
welding process to a greater extent. CAD: It is called as
Computer-aided Design. It is used to design the job for
welding. Here computers are used to design the workpiece
and how the welding is performed on it.

5.Shielding Gas: A shielding gas may be used during the welding

process in order to prevent the w/p from oxidation

Types of Laser Used

1. Gas lasers: It uses mixtures of gases as a lasing medium

to produce laser. Mixtures of gases such as nitrogen,
helium, and co2 are used as the lasing medium.
2. Solid-state laser: it uses several solid media such as
synthetic ruby crystal (chromium in aluminum oxide),
neodymium in glass (Nd: glass), and neodymium in
yttrium aluminum garnet (Nd-YAG, most commonly used).

Fiber laser: The lasing medium in this type of laser is optical fiber
itself.

Characteristics of Laser Beam

Welding
1. The power density of laser beam welding is high. It is of the
order 1 MW/cm2. Because of this high energy density, it has
small heat-affected zones. The rate of heating and cooling
is high.
 2. The laser beams produced are coherent ( having the
same phase) and monochromatic ( i.e. having the same
wavelength).
3. It is used to weld smaller sizes spot, but the spot sizes can
vary from .2mm to 13 mm.

The depth of penetration of the LBW depends upon the amount of

power supply and location of the focal point. It is proportional to
the amount of power supply.

Working

• First, the setup of welding machine at the desired location

(in between the two metal pieces to be joined) is done.

• After setup, a high voltage power supply is applied to the

laser machine. This starts the flash lamps of the machine
and it emits light photons. The energy of the light photon is
absorbed by the atoms of ruby crystal and electrons get
excited to their higher energy level. When they return back
to their ground state (lower Energy state) they emit a
photon of light. This light photon again stimulates the
excited electrons of the atom and produces two photons.
This process keeps continue and we get a concentrated
laser beam. This high concentrated laser beam is focused
to the desired location for the welding of the multiple
pieces together. Lens is used to focus the laser to the area
where welding is needed. CAM is used to control the
 motion of the laser and workpiece table during the
welding process.

As the laser beam strikes the cavity between the two metal pieces
to be joined, it melts the base metal from both the pieces and
fuses them together. After solidification, we get a strong weld.This
is how a laser Beam Welding Works

Advantages

• It produces high weld quality.

• LBW can be easily automated with robotic machinery

for large volume production.

• No electrode is required.

• No tool wears because it is a non-contact process.

• The time taken for welding thick section is reduced.

• It is capable of welding in those areas which are not

easily accessible.
• It has the ability to weld metals with dissimilar physical

properties.

It can be weld through air and no vacuum is required.

Disadvantages

• The initial cost is high. The equipment used in LBW has a

high cost.
• High maintenance cost.
• Due to the rapid rate of cooling, cracks may be produced
in some metals.
• High-skilled labor is required to operate LBW.
• The welding thickness is limited to 19 mm.
• The energy conversion efficiency in LBW is very low. It is
usually below 10 %.
 • Application
• Laser beam welding is dominant in the automotive industry.

It is used in the area where large volume production is

required.

• Electron Beam Welding

Electron beam welding (EBW) is a welding process in which a beam of high

velocity electrons is applied to the materials being joined or fused. When these

high velocity electrons impact the workpieces, the kinetic energy of the electrons

is transformed into heat, which melts the workpieces.

The first practical electron beam welding machine was developed by a

German physicist Karl-Heinz Steigerwald in 1958. In order to prevent the
distortion of the electron beam, the electron beam welding is performed in
vacuum

Working Principle of Electron Beam Welding

In electron beam welding, when a cathode in a vacuum is heated by a filament, it
emits a beam of high velocity electrons. These electrons are further accelerated by
voltage and are converged by an electromagnetic coil. When the electron beam
strikes the workpiece, the kinetic energy of the electrons is converted into heat. This
heat energy generated is then utilized for welding process.
For a typical electron beam welding machine, the diameter of the beam spot is about
0.2 mm. The electron beam welding allows less distortion, as the heat applied to the

area around the weld is low.

Advantages of Electron Beam Welding

The advantages of the electron beam welding are given as follows −
• The electron beam welding process eliminates the atmospheric
contamination of both the weld zone and the weld bead, as it is
performed in the vacuum.
• Electron beam welding consumes low power, therefore, its operating
cost is low.
• It produces narrow electron beam that reduces the distortion of the
workpiece.
• Electron beam welding is the only process that can be used to join high
temperature metals like columbium.
• Electron beam welding has high deposition rate. Therefore, its single
pass can produce welds of excellent quality.
Electron beam welding produces deep penetration with very less distortion.
Applications of Electron Beam Welding
Some of the applications of the electron beam welding are given as follows −
• The adjustment of penetration can be controlled by controlling the
electron beam output, thus the electron beam welding is applicable to
a wide variety of base materials, from thick to thin sheets.
• Metals having high melting points like tungsten can also be welded by
using the electron beam welding.
• Electron beam welding can be used for active metals such as titanium
which may oxidize during the welding process.
 • Electron beam welding is widely used in various industrial applications
such as for welding of electronic components, bridges, aircraft parts,
ship’s shells, etc.

Disadvantages:
• High capital or set up cost.
• High skilled labor required.
• Frequently maintenance required.
• Work pieces size is limited according to vacuum chamber.
• It cannot do at site due to vacuum
•
•

Ultrasonic Welding
Ultrasonic Welding (USW) is a welding technique that uses
ultrasonic vibration of high frequency to weld the two pieces
together. It is most commonly used to weld thermoplastic
materials and dissimilar materials. Metal with a thin section can
also be welded with USW.

Principle
It works on the basic principle of energy of ultrasonic wave. Ultrasonic vibration creates
a dynamic shear stress between the contacts of two work piece. Due to local plastic
deformation and heat generate due to friction between contact surfaces, joint formation
will take place at the interface.
. Equipment’s:
Power Supply:
The ultrasonic welding needs high frequency and high voltage power supply. This
power is needed by the transducer to generate vibrations

Transducer:
Transducer is a device which can convert high frequency electric signal into high
frequency mechanical vibration. This is connected with the welding head. The converter
or piezoelectric transducer used in this welding process.

Booster and Horn:

The mechanical vibration created by the transducer is supplied to the booster which
amplifies this vibration and supply to the horn. Horn is a device which supply this
amplified vibration to the welding plates

Fixture or clamping devices:

This device is essential in the ultrasonic welding. This uses either electrical, hydraulic,
pneumatic or mechanical energy to hold the plates into desire location

Working:
▪ At the start, high frequency current passes through a piezoelectric transducer.
This transducer converts high frequency electrical signal into mechanical
vibration.
▪ This vibration further supplied to the booster which amplify its frequency.
▪ The amplified high frequency vibration passes through horn which is in contact
with welding plate.
▪ This welding creates lap joint. One plant of the weld is fixed into fixture and other
one is in direct contact with horn. These plates are fixed under moderate pressure
force.
▪ The horn supply high frequency mechanical vibration to the welding plate.
▪ Due to this vibration, oscillation shear force act at the interface between welding
plates which result elestoplastic deformation at interface.
It also create a localize temperature rise due to mechanical force and friction. This heat
helps in plastic deformation at interface and makes a strong joint without

Advantages:
▪ This welding can be easily automated and fast.
▪ This produces high strength joint without applying external heat.
▪ This is clean and provides good surface finish after welding.
▪ Ultrasonic process used to weld wide variety of dissimilar metal.
It does not develop high heat so there is no chance of expel molten metal form joint.

Disadvantages:
▪ It does not weld thick harder metal. The thickness of welds about 2.5 mm for
aluminum.
▪ Tooling cost for fixture is high and they also need special design.
▪ The vibration generates through transducer, can damage electronic component.

Applications:
▪ This welding is used in fabrication of nuclear reactor components.
▪ It is used in automotive industry for key, head lamp parts, button and
switches etc.
▪ Ultrasonic is used in electronic industries like armature winding, switches
etc.
▪
▪ melting of work piece or using filler metal.
▪

Plasma arc welding

Plasma arc welding (PAW) is a welding process in which the electric arc is formed
between an electrode and the workpiece. The electrode used in the plasma arc
welding is usually but not always made of sintered tungsten. The process of plasma
arc welding was discovered by Robert Merrell Gage in 1957.
By positioning the electrode within the body of the welding torch, the plasma arc
can be separated from the shielding gas envelope. Then, the plasma is forced
through a fine-bore copper nozzle which constricts the arc and the plasma exits the
nozzle orifice at high velocities and a temperature approaching 2000 °C.

Principle:
The hot ionized gases are known as plasma. When a sufficient amount of energy provided
to any inert gas, some of its electrons breaks free from its nucleus but travel with it. After
the electrons leave, the atoms are converted into hot ionized state. It is most common
state of matter witch is known as fourth state of matter. These ionized atoms have high
heat contain which is further used to join two plates. This is basic principle of plasma arc
welding. This welding is extended form of TIG welding in which, a non-consumable
tungsten electrode is used to produce arc. This arc heats up the inert gases which are
provided from inner orifice around tungsten electrode. The heating temperature is about
30000 degree centigrade at which the gas converts into ionized form. This hot ionized
gas further used to create a welding joint by fusion.
▪

▪ Power Source:
▪ PAW process needed a high power DC supply to generate electric spark in between
tungsten electrode and welding plates (For transferred PAW Process) or in between
tungsten electrode and discharge nozzle (For Non-transferred PAW process). One of the
main features of plasma arc welding which make it different from TIG, is its low ampere
welding capability. This welding can weld at low ampere of about 2 amp and maximum
current which it can handle is about 300 amp. It needs about 80 volts for proper working.
The power source consist transformer, rectifier and control console.

▪ Plasma arc torch:

▪ This is most important part of PAW process. This torch is quite similar as used in TIG
welding but too complex. It consist four main parts which are tungsten electrode, collets,
inner nozzle, and outer nozzle. The tungsten electrode is hold by the collet. The collet is
available in varying diameters. The inner gas nozzle supply inert gases inside the torch to
form plasma. The outside nozzle supply shielding gases which protect the weld area from
oxidation.

▪ Non-transferred plasma arc welding:

▪ In this welding process, straight polarity DC current is used. In this process, the tungsten
electrode is connected to the negative and the nozzle is connected to the positive pole.
The arc produces between tungsten electrode and nozzle inside the torch. This will
increase the ionization of gas inside the torch. The torch transfers this ionized gas for
further process. It is used to weld thin sheets.

▪
 ▪ Transferred plasma arc welding:
▪ This process also uses straight polarity DC current. In this process, the tungsten electrode
is connected to the negative terminal and the work piece is connected to the positive
terminal. The arc is produces between tungsten electrode and work piece. In this process
both plasma and arc transferred to the work piece which increases the heating capacity
of process. It is used to weld thick sheets.

Working
▪ First the work pieces are properly cleaned. The power source supply power which
produces arc between tungsten electrode and nozzle, or tungsten electrode and
workpiece.
▪ The tungsten electrode gives a high intense arc which is used to ionization of gas
particles and converts orifice gases into plasma. This hot ionized gas is supplied
to the welding plates from a small orifice.
▪ The shielding gases like argon etc. are supplied through pressure valve and
regulating valve to the outer nozzle of welding torch. These gases create a shield
around the welding area which protect it from atmospheric gases like oxygen,
nitrogen etc.
▪ The plasma strikes the welding plates and fuses it into one piece. Next the welding
torch is moved in the direction of welding.
▪ If the welding required filler material, it is fed by the welder manually.

Application:
▪ This welding is used in marine and aerospace industries.
▪ It is used to weld pipes and tubes of stainless steel or titanium.
▪ It is mostly used in electronic industries.
▪ It is used to repair tools, die and mold.
▪ It is used to welding or coating on turbine blade

Advantages:
▪ High welding speed.
▪ High energy available for welding. It can be easily used to weld hard and thick
work pieces.
▪ The distance between tool and work piece does not effects the arc formation.
▪ Low power consumption for same size weld.
▪ More stable arc produced by PAW method.
▪ High intense arc or high penetration rate.
▪ It can work at low amperage.

Disadvantages:
▪ Higher equipment cost.
▪ Noisy operation.
▪ More radiation.
▪ High skill labor required.
 ▪ High maintenance cost.
Explosive welding
Explosive welding is the type of solid-state welding in which two dissimilar
metals are welded together by using a higher impact force generated by the
explosion of explosive materials.

It is the type of solid-state welding in which the material is not melted for the
welding and also it does not use any filler material.

The process is also known as the explosive cladding process as it is used to

apply the cladding material layer onto the base material. The explosive
welding can be used for protecting corrosive material like carbon steel by
covering it with a layer of non-corrosive material like stainless steel.

working principle
▪ in explosion welding, the flyer plate is arranged at a certain distance
from the base plate for getting momentum to the flyer plate.
▪ The flyer plate is accelerated by the use of explosives, therefore it hits
the base plate at a higher velocity and due to this highest impact,
the plastic deformation and molecular diffusion are happened in
between two plates. And hence it can create the weld joint between the
two dissimilar metals.
▪ ) Target plate/ Base metal: It is the plate on which the cladding has to
be done. The target plate is mounted onto the anvil.
▪ 2) Flyer plate: The flyer plate is made up of cladding material and it has
less thickness in comparison with the target plate.
The flyer plate may be parallel to the base plate or kept at a certain
angle with the base plate.
▪ 3) Buffer plate: It protects the flyer plate from erosion due to the
explosion.
▪ 4) Explosive material: The explosive material used for explosive
welding is maybe RDX or TNT or any other explosives. The selection of
explosive material is based on the magnitude of impact to be generated
for welding.
▪ 5) Stand-off distance: The stand-off distance is the distance between
the base plate and flyer plate kept for the movement of the flyer plate
over the base plate.
▪ 6) Stand-off angle: In the case of material that can not weld by using
constant stand-off distance, therefore for this material the flyer plate is
kept at a certain angle over the base plate. This angle is known as a
stand of angle.
Construction
The target plate/base plate is fixed over the anvil to support it during the
explosion.

2) The surface of the target plate and flyer plate are made clean from all
impurities to avoid the generation of oxides.

3) After that the flyer plate is kept over the base plate by keeping stand-off
distance and stand-off angle between these two plates. the standoff distance
is about 0.5 to 1 times the thickness of the flyer plate.

4) The buffer plate is placed over the flyer plate to protect it from erosion.

5) After that the layer of explosive material is placed over the buffer plate with
the detonator arranged at one end.

Explosive welding working

▪ The detonator helps to ignite the explosive material. The flame is
initiated at one end of the flyer plate and propagate over the surface of
the plate.
▪ Due to the explosion, the flat plate moves at a higher velocity toward the
base plate/ target plate.
This creates a high impact between the base plate and flyer plate.
▪ Therefore the plates undergo plastic deformation and molecular
diffusion which results in weld joint between two plates.
▪ The strength of the weld joint depends on the impact generated by the
explosive material

advantages
▪ It is easy to weld dissimilar metals which can not weld by using other
methods.
2) The welding takes place in a solid state of materials.
3) In this process, the parent properties of the material are not affected.
4) It is useful for welding large surfaces.
5) it is useful in the cladding of a protective layer over a base metal.
6) For explosive welding, highly skilled labor is not required.
7) It requires minimum fixtures.
8) The process of explosive welding is simple.
disadvantages
▪ It is used only for a ductile material.
2) Fire safety precautions are required due to the use of explosives.
3) It is used only for simple geometric shapes.
4) The method is not useful for brittle material.
5) Licence is necessary for using explosives.
6) The explosion creates a high level of noise and ground vibration.
7) This method is not suitable for thick flyer plates.

applications
1.Welding of large flat plates
2) Cladding of plates for prevention against corrosion.
3) To join pipes and tubes of dissimilar metals
4) Joining of cooling fins