Does Laser Welding Work With Tubes?

Laser tube welding technology has revolutionized how manufacturers join tubular components, delivering unprecedented precision, speed, and quality. At iGoldenLaser, we understand that modern industries demand welding solutions that combine strength, aesthetics, and efficiency. Laser tube welding machines meet these requirements while opening new possibilities for product design and manufacturing processes that traditional welding methods simply cannot achieve.

Does Laser Welding Work With Tubes?

Yes, tubes are easy to weld with laser welding. Laser welding is fast and enables neat root passes without leaving a gap.

Why laser welding works well for Tubes

Laser welding is ideal for tubes because it can do a good root pass in one operation. Fiber lasers can weld stainless steel, aluminium and steel tubes with wall thickness up to 6mm in one pass. All the parameters can be controlled repeatably, so once set up, laser welding will deliver exactly the effect you require. This can include pulsed welding to achieve the TIG “stack of dimes” look.

A rotary is the best method of laser welding tubes.  This is fast and repeatable.  Our double wobble laser welding head has advantages in most situations, and allows quick optimization of the weaving pattern to get a beautiful and strong weld.

Using a rotary works well for flanges, butt welding, lap welding, and generally welding anything round including load cells.

Does laser welding work on box section tubes?

Box sections weld fine with a laser welder.  For aluminum extrusions with square corners fusing is the easiest option.  Simply butt them up and use the autogenous process.

For rectangular steel tube (box section) the only thing to watch is filling of gaps due to the radius of the tube corners.  If the radius is large, a twin wire feeder is the best method.  This allows the operator’s speed to be set by the wire feeder, while two 0.063″ wires (1.6 mm) feed out and are melted into the weld.

For larger gaps it is also possible to use a single wire feeder and hold the gun back so it builds up a larger bead, and control the melt pool more like a MIG.  However for box section tubes with a large edge radius the large gap is best welded with our twin wire feeder option.

How to seal round load cells with laser welding?

Load cells can be tubular and are always a prime candidate for laser welding.  Load cells are precisely made and require assembly with good sealing of the cover plate and minimal distortion, which could affect their calibration.

Laser welding is the ideal process for welding load cell cover plates in position.  This image shows a very fine laser weld done with a rotary and hand held laser welding head.  At only 0.040″ wide, this is a small weld.  However the best machine for this job is one of our popular multi-axis CNC laser welders, which gives the best possible process repeatability and tuneability.  The weld can be tuned to be as small as you require for the delicate job at hand.  We recently delivered a pulsed version for welding 0.004″ (0.1mm) inconel and stainless steel foils, which the customer was extremely happy with.

What is the maximum thickness for tube laser welding?

Our 3kW systems can laser weld up to quarter inch or 4 gauge stainless steel, aluminum and steel at high speed with full penetration in one pass.

2kW machines are suitable for laser welding up to 4mm at high speed, or thicker by slowing down.

The image on the left shows 1/8″ (3mm) wall thicknes tube that was assembled wtih a spigot to control radial runout.  Control of runout or concentricity is important when setting up and helps ensure a good end result.

Our customer ground this part back so it was flush and was very happy with the result.

Laser welding tubes are a highly efficient and precise method used in automotive, aerospace, and manufacturing industries. The process utilizes a concentrated laser beam to fuse metal or thermoplastic components, offering advantages over traditional tube welding techniques like TIG or MIG welding. Laser welding benefits pipe and tube manufacturing because of its speed, precision, and minimal heat-affected zones, which help maintain structural integrity and reduce material distortion.

Different tube profiles, including round, square, rectangular, and custom shapes, affect laser welding by presenting unique challenges in seam alignment, heat distribution, and dimensional control. For example, round tubes require precise seam tracking to ensure weld accuracy, while square or rectangular profiles require careful heat management at corners to prevent burning or incomplete weld penetration.

Safety is paramount when performing welding tubes with laser technology. Essential safety equipment includes laser safety glasses, welding helmets, protective clothing, and fire-resistant gloves. Establishing a controlled laser safety area with proper ventilation, fume extraction systems, and laser safety barriers is critical to protecting operators and nearby personnel during tube welding operations.

Laser welding excels at handling various materials, including stainless steel, carbon steel, aluminum, titanium, copper, and brass. These materials are used in tube and pipe welding for durability, corrosion resistance, and strength. The precise control of the laser allows for high-quality welds on thin-walled tubes and complex profiles while reducing post-weld processing.

Can you Weld Tubes using Hand-held Laser Welder?

Yes, you can weld tubes using a hand-held welder. The accuracy and adaptability of hand-held laser welders make them perfect for a wide range of uses involving pipes and tubes.

Using a hand-held laser welder on pipes or tubes has many benefits, such as portability. Hand-held laser welders allow operators to perform welding tasks in various locations, on-site or confined spaces, and are helpful for pipes or tubes installed in hard-to-reach areas. Precision is another benefit, as the focused laser beam delivers narrow, clean welds with minimal heat-affected zones, making the process ideal for thin-walled tubes or delicate materials that require careful handling.

The speed of laser welding offers a clear productivity advantage when dealing with long pipe sections or multiple tubes. The rapid process ensures minimal downtime and reduces project time compared to traditional methods. The reduced heat input of laser welding minimizes distortion, meaning the material is less likely to warp or suffer structural integrity issues during welding.

Superior weld quality is an additional perk. Laser welders produce clean welds with minimal spatter, reducing the need for post-weld cleaning or finishing. The portability and versatility of hand-held laser welders used for spot and seam welding make them ideal for a wide range of tube and pipe welding applications. Laser welding is energy-efficient, cutting operational costs while maintaining high levels of safety due to built-in protective attributes and reduced exposure to heat and fumes.

How does Laser Welding Work for Tubes?

Laser welding works for tubes by employing a focused, high-energy laser beam to melt and fuse the edges of tubular materials, creating a seamless joint. The process begins with precisely aligning the tube’s edges and applying a laser beam at the seam. The heat from the laser rapidly melts the material, and as it cools, the molten edges fuse, forming a strong weld. The laser’s focused energy minimizes the heat-affected zone, ensuring the surrounding material remains intact while the joint solidifies into a continuous seam.

Laser welding offers advantages over traditional methods like TIG welding. It is notably faster, achieving welding speeds of up to 16 meters per minute for specific materials, drastically reducing production time. Its precision allows for minimal heat-affected zones, ensuring the weld is clean and less distortion-prone. The process is highly versatile and joins various materials, such as stainless steel and mild steel, making it suitable for diverse industrial applications. Its energy efficiency with diode lasers results in lower operating costs, and the process requires less post-processing, reducing the need for additional machining. Laser welding is automation-friendly, which makes it a preferred method for industries relying on high production rates, such as automotive manufacturing.

The first step is to prepare the material and cut it to the desired size, with the edges cleaned and aligned for welding. The laser welding system is calibrated based on the material’s properties and the appropriate settings. An inert shielding gas, such as argon, keeps the weld area from rusting while welding. It keeps the weld clean. The laser beam is directed precisely along the seam, melting the edges together, and the area cools rapidly without additional cooling measures. The welded tube undergoes quality inspections, such as the drift-expanding test, to verify the integrity of the weld. Minimal post-processing is required to enhance the weld quality further.

Is it Difficult to Laser Weld Tubes?

No, it is not difficult to laser weld tubes. Laser welding is suited for tube welding due to its precision, speed, and adaptability across different materials. The process is straightforward and efficient, allowing clean root passes, single-pass welding, and excellent control over parameters, resulting in high-quality and repeatable welds.

Laser welding tubes pose challenges because of the material’s complexity and shape. For example, rectangular steel tubes with large corner radii present difficulties filling gaps, requiring specialized techniques such as twin wire feeders to achieve uniform welds. Laser welding works excellently with many materials, but aluminum and other materials that reflect light make the process more difficult. These materials require specific laser types or adjusted parameters to achieve optimal welding results, as their reflective surfaces interfere with the laser beam’s absorption.

Material thickness plays a role in the difficulty of welding tubes. Laser welding works excellently on thinner materials, but for very thick tubes, it takes more than one pass, which slows down the process and makes it more complicated. Proper setup and alignment are critical to ensure concentricity and avoid issues like runout in precision applications such as load cells, where accuracy is paramount. Complex geometries or joint designs require more careful planning and optimization of welding parameters, but these challenges are manageable with proper technique.

What Type of Laser is Most Effective for Welding Tubes?

Fiber lasers are the most effective type for welding tubes in applications involving high-value tubes, pipes with heavier wall thicknesses, and high-speed welding operations. The effectiveness stems from multiple variables that make fiber lasers well-suited for these scenarios.

Fiber lasers provide excellent process stability when welding thicker materials. They produce less spatter during welding, which is crucial when working at high speeds or with heavier walls, as it ensures a cleaner weld. Using plasma generated by fiber lasers during keyhole welding improves the weld penetration and efficiency even further by increasing the laser beam’s absorption by the material.

Fiber lasers tend to perform better in high-speed applications due to their ability to maintain stability without generating excess spatter, a common issue with solid-state lasers, such as fiber lasers, when used at high power levels. Using fiber lasers to weld thicker tube materials is the way to go for industries that value efficiency, cleanliness, and precision.

CO2 lasers are beneficial in specific applications but not for welding highly reflective materials like aluminum or copper. CO2 lasers were state of the art ten years ago but have been replaced by fiber lasers due to the many advantages of fiber lasers.

Fiber lasers offer advantages such as higher wall plug performance, better beam delivery flexibility, and improved absorption rates for reflective metals.

What Type of Laser is Most Effective for Welding Tubes?

The techniques for effective Laser Welding Tubes are listed below.

• Surface Preparation: Clean and prepare tube surfaces before welding to improve laser absorption and enhance weld quality by reducing impurities.

• Shielding Gas Optimization: Select appropriate shielding gases, like argon, to protect the weld pool from oxidation, minimize spatter, and ensure stable arc performance.

• Design Optimization: Design components specifically for laser welding, ensuring proper joint geometry, fit-up, and accessibility for the laser beam to improve welding success.

• Material Selection: Choose materials compatible with laser welding processes, considering factors like melting points, thermal conductivity, and the tube’s composition.

• Heat Input Control: Manage heat input carefully by adjusting focal length, focus position, and spot size to prevent tube distortion or surface damage during welding.

• Power Density Optimization: Control the power density of the laser to adjust weld penetration depth and width, balancing between deep and shallow welds depending on requirements.

• Pulse Duration Management: Adjust the pulse duration to influence the size of the heat-affected zone (HAZ), using shorter pulses for smaller HAZ or longer pulses when necessary.

• Welding Speed Adjustment: Optimize the welding speed to balance high productivity and maintain weld quality, adjusting speed based on material thickness and process demands.

• Beam Shaping: Utilize advanced beam shaping technologies to precisely control heat input, improve deep penetration welding, and minimize distortion in tube welding.

• Hybrid Laser Welding: Combine laser welding with conventional arc welding for improved weld quality, higher productivity, and better performance with thicker tube materials.

• Adaptive Control Systems: Use adaptive control systems for real-time power, speed, and beam shape adjustments to optimize productivity and ensure high-quality welds.

• Keyhole Welding Technique: Apply the keyhole welding technique with high-power lasers for deep, narrow welds in thicker tubes requiring significant penetration.

• Heat Conduction Welding: Use heat conduction welding with lower-power lasers to achieve smooth, visually pleasing welds on thin tubes or when weld strength is not critical.

• Parameter Monitoring: Monitor key welding variables, such as temperature, melt pool size, and beam pattern, using sensors and cameras to ensure consistent weld quality.

Can you Laser Weld Tubes Under Water?

Yes, you can laser weld tubes underwater. The technique has been developed for various underwater repair and maintenance applications for tube-plate structures made from aluminum alloys. The process has proven valuable in scenarios where traditional underwater welding methods are more effective and challenging.

Underwater laser welding requires the creation of a localized dry environment around the welding area to protect the weld from the surrounding water. It is achieved using specialized drainage systems, which utilize compressed gas or water curtain nozzles to maintain a dry space around the tube joint. These systems create a stable environment in shallow and deep waters, ensuring the laser beam is not obstructed by water during welding.

Higher-power laser systems, like Nd:YAG or fiber lasers, are used along with drainage systems to provide enough energy for practical welding. These lasers are powerful enough to penetrate the tube material and achieve the desired weld depth, even underwater. Specialized multi-function welding heads are employed, which allow for the precise control of the welding process, including inspection and surface preparation before welding.

Using robotic systems to regulate the welding process allows for greater accuracy and circumvents the difficulties of working in an underwater setting. The robots operate under challenging conditions and ensure the welding head is positioned correctly on the tube. Inert shielding gases protect the weld pool from water contamination, helping maintain the weld quality.

The process involves creating a dry area, positioning the laser welding head, initiating the laser beam to melt the tube materials, and controlling parameters like power, speed, and focus to achieve high-quality welds. Rapid cooling occurs due to the surrounding water, which, if managed well, results in solid and deep welds with minimal defects.

What are the Advantages of Laser Welding for Tubes?

The advantages of laser welding for tubes are listed below.

• Energy Efficiency: The process requires less energy than traditional methods, reducing operational costs and contributing to more sustainable tube manufacturing practices.

• Non-Contact Process: Laser welding is a non-contact technique that enables welders to weld in inaccessible places of tubes, reduces contamination risks, and wears down equipment.

• Superior Weld Strength: Laser welding produces strong, durable welds suitable for high-pressure applications, enhancing the structural integrity and performance of the final product.

• High Precision and Control: Narrow, deep welds, little distortion, and exact control over heat input and parameters are all possible with laser welding’s high precision and control.

• Clean and Precise Welds: The process produces smooth, aesthetically pleasing welds with minimal need for post-weld finishing, reducing the risk of contamination in the weld area.

• Minimal Heat-Affected Zone (HAZ): Laser welding minimizes the heat-affected zone, reducing thermal distortion, preserving the base metal’s properties, and making it ideal for heat-sensitive materials.

• High Welding Speed: Laser welding achieves high speeds, over 10 meters per minute, increasing productivity, reducing production time, and enhancing throughput in tube manufacturing.

• Versatility in Materials: Laser welding is suitable for a wide range of materials, including steel, stainless steel, and aluminum, and enables the joining of dissimilar materials.

• Automation Compatibility: Laser welding is easily integrated into automated production lines, ensuring consistent, repeatable welds, improving quality control, and boosting efficiency.

• Flexibility in Joint Design: Laser welding accommodates various joint configurations, enabling complex tube shapes, geometries, and custom designs.