What is the difference between conduction and keyhole welding?

Conduction welding uses lower power to melt and fuse material surfaces, creating wider, shallower welds. Keyhole welding uses higher power to create deep penetration through vaporization, ideal for thicker materials and butt joints.

What shielding gas should I use for laser welding?

Argon is most common for stainless steel and aluminum, providing good protection and weld quality. Helium offers deeper penetration for thick materials. Nitrogen is economical for mild steel. Some applications use no shielding gas for thin materials.

How much power do I need for laser welding?

1-2kW fiber lasers handle most thin sheet metal (0.5-3mm). 2-4kW is ideal for general fabrication (2-6mm). 4-10kW+ is needed for thick plate welding and high-speed production. Higher power increases speed but also equipment and operating costs.

Why does welding cost more than cutting?

Welding requires higher precision, slower speeds, shielding gas, potential pre/post-heat treatment, and more stringent quality control. Setup time per piece is often higher, and skilled operators command higher wages. The profit margin also reflects the higher risk and quality requirements.

What factors affect welding speed?

Material type and thickness, laser power, welding process (conduction vs keyhole), joint fit-up quality, required penetration depth, and quality requirements. Aluminum welds faster than stainless steel. Keyhole welding is faster than conduction for thick materials.

Laser Welding Cost Calculator

Calculate accurate laser welding costs for all processes and materials. Optimize pricing with comprehensive cost analysis including gas, power, and labor. See our power consumption reference for energy costs.

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Welding Optimization Tips

Process Selection

• Use keyhole for thick materials (>3mm)
• Conduction mode for thin sheet (<2mm)
• Seam welding for continuous joints
• Spot welding for quick tack welds

Cost Reduction

• Maximize batch sizes to reduce setup time
• Use nitrogen instead of argon for mild steel
• Optimize gas flow (15-20 L/min typical)
• Regular maintenance prevents costly failures

Quality Improvement

• Ensure proper joint fit-up (gap <0.2mm)
• Use appropriate shielding gas for material
• Preheat thick sections to prevent cracking
• Post-weld heat treatment for stress relief

Pricing Strategy

• 40%+ margin for complex welding jobs
• Charge setup fees for small batches
• Premium pricing for certified welds
• Volume discounts at 50+ pieces

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Welding Optimization Tips

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