Hybrid Laser/GMAW Welding

Development and implementation of high productivity processes can have a profound effect on the overall cost of manufacturing. This is especially true for large or thick section structures that often require slow, time-consuming welding processes. One new, high productivity process gaining popularity is hybrid laser/GMAW welding. The hybrid laser/GMAW welding combination results in a synergistic process that combines the positive attributes of both individual processes. Overall advantages of the hybrid laser/GMAW process can include:

• Reduced weld metal requirements through narrower joint preparation
• Reduced distortion
• Better control of weld nugget properties
• Better retention of base metal properties
• Reduced welding time versus conventional arc welding processes

EWI has recently completed the installation of a new 10kW IPG fiber laser. This state-of-the-art laser technology allows EWI to expand the development of both autogenous and hybrid laser/GMAW into thicker sections. The benefits of the 10kW fiber laser include excellent beam quality for high energy density welding, high electrical efficiency, ability to pulse, minimal floorspace requirements, and portability.

Single pass butt welding capability for this laser is in excess of ½ in. for carbon steel. The addition of filler metal from the GMAW process can greatly improve the gap bridging capability of autogenous laser processing, thereby reducing the cost and complexity involved with precision edge fitup, which would otherwise be required. Furthermore, the addition of filler material can aid in altering the weld metal composition to improve overall weld joint performance.

Recent EWI work has shown great success in hybrid laser GMAW of several materials, including; carbon steel, titanium, and aluminum. One unique benefit with this process in welding titanium is arc cathode stabilization, supported by the high intensity laser focal spot, which allows the welding arc to perform in a smoother, faster, and more consistent manner, thereby increasing overall productivity and reducing associated welding rework. While this cathode stabilization is most pronounced in titanium, it can also be used to great advantage in laser hybrid GMAW of aluminum, where filler metal is often required to avoid solidification defects.

Given the continually evolving advancements in high-power laser capabilities and the range of products that may benefit from this technology, the opportunities for hybrid laser/GMAW application are vast. EWI’s collective experience with both processes puts us in a perfect position to expand this important, evolving capability.

For more information, please contact John King at 614.688.5232 or john_king@ewi.org.