Solutions To Common Handheld Laser Welding Problems

Handheld laser welding, with its high efficiency and portability, has long been a powerful tool for sheet metal processing, hardware manufacturing, and other industries. However, many customers report encountering minor issues when first using it, often due to a lack of mastery of the techniques: issues such as porosity in the weld, lack of penetration, and misaligned red light.

However, to minimize downtime, if you experience any of the following issues, please don't rush to report a repair. It may simply be a "false fault." No need to wait for a professional repair person to come, you can easily fix the problem yourself, saving time and effort.

Common Problem Solutions

1. Suddenly weakened during welding and unable to fuse

(1) Check whether the protective lens at the front of the welding gun is damaged, including but not limited to the protective lens, focusing lens, collimating lens, and reflective lens. Damage to any one or more of these lenses may cause the above situation.

(2) Check whether there is dust or flying debris on the lens, and clean or replace it immediately.

(3) Check whether the scale tube at the gun head has moved. Generally, the scale tube is at zero. You can move the scale tube forward and backward to make corresponding adjustments according to the specific welding situation.

2. The protective lens will wear out quickly in a short period of time, and burn spots and black spots will appear. Please adjust as follows:

(1) Increase the air pressure appropriately.

(2) Avoid vertical welding with the welding head, and try to ensure 45° welding.

(3) Set the parameters according to the "slow rise and slow fall" gradual principle, for example, the on/off air delay is 200-500ms, the on/off light power is 20%, and the on/off light gradual time is 200-300ms.

(4) The quality of the protective lens itself also determines its durability. It is recommended to use the original lens.

3. The wire feeder is jamming or not feeding smoothly.

Cause Troubleshooting:

Check the wire feed roll model: U-groove wire feed roll for aluminum wire, V-groove wire feed roll for stainless steel wire.

Check for debris on the wire feed rolls?

Check that the wire being fed is deformed?

Solution:

Replace the appropriate wire feed roll and adjust the tension.

If using aluminum wire, replace it with a dedicated graphite wire feed tube to increase the wire diameter.

4. Black weld, heavy smoke, no fuse

Solution:

(1) Check whether the gas pressure is sufficient? whether the welding wire used matches the raw material? and whether there is any coating, oil stain, oxide layer, etc. on the welding raw material?

(2) Check whether the equipment lens is damaged and whether the scale tube is at 0?

※ Before welding, clean the oil stain, packaging, coating, etc. on the surface of the welding material to avoid affecting the welding effect and causing fire.

5. Various signal light alarm problems

Cause analysis:

Temperature alarms may be caused by thermistor not being properly plugged in, thermistor being damaged, or lens being damaged, while water chiller, air pressure, or laser source alarms are usually related to incorrectly set levels.

Solution:

(1) For temperature alarms, it usually means that the lens temperature exceeds the standard.

In this case, you should first check whether the lens is intact?

If there is a problem, pls replace it.

If the lens is normal, you can temporarily block the alarm in the "Settings" column of the control panel and set the corresponding lens temperature alarm threshold to "0" and save it.

(2) For level alarms, it is common for water chiller, air pressure, or laser source.

This type of alarm is often caused by improper alarm level settings.

In this case, you only need to adjust the corresponding alarm level settings.

6. The red light is not centered or deviates from the center point.

Solution:

First try to adjust the red light marker to a point light and carefully check whether the red light is indeed in the center of the welding nozzle.

If deviation is found, the following adjustment measures can be taken: (1) Software settings: Enter the laser center point offset option and make fine adjustments according to the direction of the red light deviation. If the red light is deviated to the left, enter a positive value.

If it is deviated to the right, enter a negative value. After the adjustment is completed, recheck the red light position.

(2) Mechanical adjustment (professional guidance required): If the software adjustment cannot center the red light, professional mechanical adjustment may be required. In this case, it is recommended to contact professional after-sales personnel for assistance.

Handheld laser welding is a fast and efficient welding method with significant advantages.

The final weld quality depends largely on the welding parameters, which need to be selected and adjusted according to the actual situation and welding requirements.

Only by properly selecting and adjusting the parameters can high-quality welding be achieved.