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Laser welding in serial production – how to move from process trials to a stable process? (part I)
Producing a sound weld during process trials is an important stage in process development. However, it does not yet mean that the technology is ready for implementation in serial production.
In the laboratory, it is possible to confirm that specific materials can be joined effectively using a given set of parameters. Under real production conditions, however, the process must cope with something much more demanding: natural part-to-part variation, the required cycle time, changing material batches, and the need to detect deviations quickly.
Therefore, the right question is not: “Can we produce this weld?”, far more important is: “Can we produce it repeatably on actual parts, at the target production rate and while meeting all product requirements?”.
Start with the function of the joint
The first stage of process development should be to define the function the joint is intended to perform and the criteria it must meet.
The requirements are different for a joint that carries mechanical loads, a joint that conducts electrical current, and a weld that is responsible for leak-tightness.
For components used, among other applications, in batteries or automotive inverters, a single weld may be required to perform several functions at the same time. In such cases, factors including mechanical strength, electrical resistance, penetration depth, joint area, the risk of cracking and spatter, and the thermal impact on adjacent components must be taken into account.
Only on this basis can the technology and process parameters be selected in an informed manner. A uniform weld appearance is one of the assessment criteria, but on its own it does not confirm sufficient penetration depth, the required electrical properties, or the absence of internal defects.
A material sample is only the beginning
Initial tests are often carried out on simple, well-prepared samples. They make it possible to assess whether the materials can be joined and to compare different process variants.
The problem arises when a result obtained on an ideal sample is treated as a production-ready process recipe.
An actual part may differ in terms of:
- material thickness and geometry,
- manufacturing tolerances,
- coating type and surface condition,
- local deformation,
- the gap between components,
- heat dissipation,
- beam access to the welding area,
- the presence of temperature-sensitive components.
Technology development should therefore be carried out in stages.
First, the feasibility of producing the joint should be confirmed. The next step is to carry out trials on actual parts. This should then be followed by reproducing the conditions of the future machine: the locating, positioning and clamping method, the optical configuration, and the sequence in which individual welds are made.
Only then do the trial results begin to reflect the conditions under which the process will actually operate.
The process must be verified on the target machine
Parameters developed during trials should not be transferred directly to the final production station without additional validation.
After the technology is transferred, factors including the optical configuration, actual spot size, focal position, beam guidance, part clamping, shielding gas, and sequence of operations may change. Therefore, an important element of scaling is to verify the process again after the target production station has been commissioned.
In one Nextomation project involving the welding of copper connections in automotive inverters, work began with tests on actual components. A prototype fixture and a dedicated clamping system were then prepared to reproduce future production conditions as accurately as possible.
The first parts were produced before the final machine was commissioned. Subsequent parts were made on the target production station, which made it possible to compare the results, adjust the settings, and prepare the process for further increases in production output.
This is what distinguishes producing a good weld from developing a complete production process.
Serial production is the next stage of validation
Technical acceptance of the production station does not mark the end of technology development.
Only a larger number of manufactured products shows how the process behaves with successive material batches, changes in product variants, station warm-up, contamination of optical and clamping components, and tooling wear. Therefore, a production-ready process should include not only the laser settings, but also procedures for inspection, cleaning, calibration, and responding to deviations. Preparing operators and the maintenance team is equally important.
They must know which elements of the production station affect joint quality and how to verify the process after changes or maintenance work.
From a sound weld to a scalable process
Scaling laser welding requires the technology to be viewed as an entire system.
Beam parameters are important, but so are product design, tolerances, surface preparation, positioning, clamping, quality control, and production organisation.
A sound weld is only the beginning. A mature process is achieved only when the required quality can be consistently achieved, measured, monitored, and maintained throughout the entire production period.
Are you scaling a laser welding process for serial production?
A repeatable process requires more than a sound weld. Key factors include joint design, part tolerances, the positioning and clamping method, a stable process window, and validation of the technology on the target machine.
During a free consultation, Nextomation experts will help assess the application’s readiness for scaling, identify the most important technological risks, and determine the scope of trials required before the process is implemented in serial production.
Consult us on scaling your laser welding process
Read also
Find out why joint geometry, gaps, and tooling can have just as much impact on process stability as the laser settings themselves.
Find out why, in serial production, a stable operating range is more important than one ideal set of parameters.
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