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How Laser Welding Eliminates 80% of your post weld clean up
Laser welding can significantly reduce post-weld cleanup by creating a deeper, narrower weld with less bead buildup, spatter, and heat distortion. Learn why the process requires less grinding and how that translates into faster production and more throughput.
9/23/20262 min read
You just paid a welder to put metal on the part — and now you're paying someone else to take it back off.
Penetration Instead of Bead Buildup
A MIG weld gets much of its usable weld geometry from the bead deposited around the joint. Too much buildup creates a convex weld that may eventually have to be ground back down. Miller specifically identifies overfilled and convex MIG beads as common weld conditions tied to process parameters.
Laser welding works differently.
A concentrated laser beam creates a narrow, deep fusion zone in the base material. Research and industry references consistently describe laser welds as having high depth-to-width ratios and deep, focused penetration.
MIG often builds the weld out. Laser drives the weld in.
That means less excess material sitting above the joint that has to be removed afterward.
Why There Is Less Spatter
MIG physically transfers molten wire across an electrical arc.
Depending on the transfer mode, droplets can short into the puddle or cross the arc irregularly. Those electrical and mechanical interruptions are one of the reasons MIG produces spatter. TWI notes that globular transfer can produce large amounts of spatter, while even short-circuit MIG requires careful control of voltage, inductance, wire speed, and stickout to minimize it.
Laser welding isn't transferring molten filler across an open arc.
The laser delivers energy directly into the joint, and filler wire is fed into the controlled molten area. That removes one of the primary mechanisms that creates spatter.
Less Heat Means Less Rework
Laser welding also concentrates heat into a much smaller area.
That produces a smaller heat-affected zone and reduces the amount of surrounding material being heated and cooled during the weld. AWS notes that laser welding's concentrated energy creates a narrow, deep joint with relatively low heat input into the surrounding material.
For post processing, that can mean:
less weld buildup to grind off
less spatter to remove
less distortion to straighten
less discoloration and cleanup
This equates to ~$11,000 per year of savings in post processing reduction over traditional welding systems for an average sized metal fab shop. (Assuming $18/hr & 15 hours per week of post-processing)
See What Laser Welding Can Do for Your Shop
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Discover the efficiency of laser welding today and unlock its potential to revolutionize your manufacturing processes. With its precision and speed, laser welding offers unparalleled advantages that can enhance your productivity and reduce costs.
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