Handheld Laser Welding Technology – An Impartial Assessment to Support Industrial Adoption
Status: Proposal
Date Announced: August, 2023
Project reference: PROP311304
Summary
Handheld laser welding is a new emerging technology. The devices promise faster, more versatile, cost effective and consistent welding results than more conventional manual arc welding processes, such as MIG/MAG or TIG welding. Handheld laser welding devices require an operator holding the system to release the beam and are equipped with safety features that shut off the beam as soon as the system moves away from the workpiece, so offer engineered safety control. However, the lack of a standardised assessment methodology and supporting data, and thus independent validation of the technology's claims, could result in industry being hesitant to adopt this potentially disruptive technology, due to absence of independent validation of its performance, robustness, safe operation and capabilities. The aim of this Joint Industry Project (JIP) is to provide independent third-party assessment and validation of handheld laser welding technology, focusing on demonstration of the ability to make sound welds, health, safety and environmental impacts (e.g. welding fume and scattered radiation), and tolerance of the process in relation to weld quality and mechanical properties. The scope of work will include benchmarking against conventional manual arc welding approaches, including MIG/MAG and TIG welding processes.
Objectives
- Indicate suitability for industrial use by investigating welding parameters and process tolerance around a range of materials, joint configurations and thicknesses, representative of targeted case studies identified by the Sponsors (up to a maximum of five case study scenarios).
- Perform weld quality (e.g. via inspection) and property (e.g. mechanical performance) assessment, in line with specifications of the targeted case studies.
- Perform a secondary emission safety case assessment around weld fume and scattered radiation characterisation, to better understand the impact on Health and Safety of operations.
- Compare laser handheld technology with a relevant more conventional manual welding approach (i.e. arc welding).
- Training and knowledge transfer through a practical workshop to demonstrate technology in action.
Benefits
The information generated will provide Sponsors with impartial technical advice on the adoption of handheld laser welding technology in their businesses, contributing to improved understanding of its appropriateness and suitability for use in their manufacturing environments. It will aid sponsors in effective process capability acquisition assessment by considering key factors across a range of case studies, including:
- Key process variables (KPVs) such as welding speed and positioning of nozzle end-effector (in relation to the workpiece).
- Related tolerances of process performance to variation in KPVs.
- Typical flaw/defect type and frequency compared with manual welding / automated laser welding.
- Non-destructive testing / inspection considerations.
- Training and familiarisation with handheld technology.
- Investment and operating costs.
This project will deliver data and information to support decisions on whether the technology is robust, safe, fast, versatile and cost effective for the Sponsors’ industrial applications. This aim is to provide a greater level of assurance for those seeking to use laser handheld technology for welding applications, helping to facilitate the adoption of this innovative technology within industry.
If you are interested in finding out more, see the PDF download. If you would like to join this JIP, please contact us.