stainlesstec offers 3D laser welding of stainless steel and aluminium for demanding parts and welded assemblies. The process delivers energy precisely and suits complex three-dimensional weld paths, delicate structures and recurring parts with high demands on process reliability and repeatability.
In laser welding, the energy needed to melt the material is delivered into the joint in highly concentrated form. Unlike conventional processes, the energy input can therefore be directed very precisely: the weld can be kept narrow and the thermal load on the surrounding material limited.
With 3D laser welding the beam can also follow complex spatial contours. That makes it possible to work not only on flat sheet metal parts but on three-dimensional parts and assemblies along defined weld paths – opening up designs where conventional processes reach their limits in terms of access, heat input or repeatability.
We do not treat laser welding in isolation: on request we also make the individual parts, do the bending, prepare the joints and carry out the subsequent work.
Advantages of 3D laser welding
Concentrated heat input
The energy goes into the weld zone locally, which keeps the heat-affected zone smaller than with less concentrated processes – of particular interest for parts where distortion and thermal load must stay low.
Narrow welds
Concentrated energy allows precise and comparatively narrow weld geometries. With a suitable design, that can also reduce the work needed to dress the weld afterwards.
Complex 3D geometries
The beam can follow defined spatial contours, which makes the process suitable for parts whose welds do not all lie in one plane.
High repeatability
Once a process is set up for an assembly, defined weld paths can be run repeatedly. That makes 3D laser welding particularly attractive for demanding small batches and recurring parts.
High process speed
On suitable applications, high welding speeds can be achieved, which can give laser welding an economic edge on recurring parts.
Laser welding stainless steel
When laser welding stainless steel, concentrated heat input can be an advantage above all on precise, distortion-sensitive parts. stainlesstec processes a range of weldable stainless grades, among them widely used materials such as:
1.4301 / AISI 304
1.4307 / AISI 304L
1.4404 / AISI 316L
1.4571 / AISI 316Ti
and any other grades a project requires. Which parameters and, where applicable, which filler metal are needed depends on material, thickness, weld geometry and the loads in service.
Aluminium can be laser welded too, though its physical and metallurgical properties place particular demands on process control and part preparation.
stainlesstec processes the common weldable aluminium alloys, among them the AlMg and AlMgSi groups. With special or high-strength alloys, weldability has to be assessed for the specific alloy and application.
With aluminium in particular, controlled energy input and a repeatable process can be valuable for precise parts.
The precision of the process places high demands on the parts. Where manual welding can absorb a certain amount of deviation as the work proceeds, a repeatable laser process needs defined conditions. The most important are:
Accurately fitting joints
Joint gap and part position have to suit the welding strategy planned.
Repeatable part geometry
For runs and small batches, the individual parts have to be made within defined tolerances.
Clean surfaces
Contamination in the joint area can affect the quality of the process.
Suitable fixtures
The parts have to be located exactly and repeatably during welding.
Design for welding
Weld path and access should ideally be matched to the process at the design stage.
This is exactly where our own sheet metal work pays off.
From the laser-cut part to the 3D laser welded assembly
stainlesstec can make the components of a welded assembly itself:
Laser cutting → punching → bending → locating the parts → 3D laser welding → finishing → finished assembly
That lets us ensure at the cutting and bending stage that the joints will suit the laser process. Locating features, lugs or tab-and-slot geometries can also be designed in so that the parts go together repeatably.
Sheet metal work and laser welding thus become one continuous process.
3D laser welding for small batches
Automated processes are often associated solely with high volumes. On technically demanding parts, however, 3D laser welding can be worthwhile at much smaller quantities. What counts is the ratio between set-up effort and recurring production.
With demanding small batches in particular, high repeatability and automated guidance of the weld path can be a considerable advantage. For a new part we therefore assess whether the programming and fixturing effort is justified by the quantity and the requirements.
Precision for demanding applications
3D laser welding suits parts where complex geometry, precise manufacturing and repeatable quality come together. Typical fields of use include:
Machinery and plant engineering
Precise enclosures, components and special structures.
Aerospace and high technology
Lightweight, complex parts with high demands on accuracy and process control.
Pharmaceuticals and special technical applications
Stainless steel components calling for precise weld paths and controlled heat input.
Defence technology
Complex parts and small batches to defined material and production specifications.
The materials, tests and documentation actually required are defined for each project.
From prototype to repeatable process
A new laser welding project starts with developing a stable process. That includes assessing:
Component geometry
Material and thickness
Joint configuration
Weld path
Component tolerances
Location and fixturing
Process parameters
Requirements for the finished joint
Once the process is defined it can be used repeatably for recurring parts. That makes it particularly suitable for companies which, after a successful first run, need consistent small batches or recurring assemblies.
Let’s talk about your project.
Send us your drawing or CAD data by email – together with material, batch size and your requirements. We will come back to you with a sound assessment.
