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Addressing Weld Burn-Through in Fiber Laser Welding Machines
szhaiwei
2025-09-06
Weld burn-through is a frequent challenge in precision joining, particularly when using a fiber laser welding machine on thin-gauge materials or assemblies with inconsistent joint fit-up. While fiber lasers deliver high beam quality and deep penetration, improper configuration can lead to excessive melt-through, compromising joint strength and part integrity.
Understanding the Causes of Burn-Through
Burn-through occurs when laser energy density exceeds the material’s capacity to dissipate heat, resulting in full melt-through of the workpiece. Common causes include excessive laser power, slow travel speed, incorrect focus position, or gaps in the joint. Materials with high thermal conductivity—such as aluminum, copper, and their alloys—are especially prone to this defect due to rapid heat accumulation at the weld zone.
Parameter Optimization
The most effective solution is precise adjustment of welding parameters. Reducing laser power or increasing travel speed lowers overall heat input. For thin materials (below 1 mm), pulsed laser modes offer superior control compared to continuous wave (CW) operation, minimizing the risk of burn-through while maintaining sufficient fusion.
Joint Fit-Up and Fixturing
Consistent contact between mating surfaces is essential. Even minor gaps can concentrate the laser energy and trigger localized burn-through. Using precision fixturing and automated clamping systems helps maintain uniform joint alignment and gap control.
Real-Time Process Monitoring
Advanced fiber laser welding machines support integrated monitoring, such as melt pool cameras and seam tracking sensors. These systems detect anomalies during welding and can trigger alerts or automatic parameter corrections, preventing continued production of defective welds.
Beam Oscillation for Heat Distribution
Beam wobbling (oscillation) spreads energy across a wider area, improving gap tolerance and reducing the likelihood of keyhole instability and burn-through.
Preventing burn-through in fiber laser welding machines requires a balanced approach: optimizing parameters, ensuring proper joint preparation, and utilizing real-time feedback. When selecting equipment, prioritize systems with flexible control and process monitoring capabilities. Suppliers like Haiwei Laser provide application-specific support to develop stable, high-quality welding processes.
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