Common Faults and Solutions of Laser Welding Machines
1.Abnormal laser output faults
The laser power is insufficient and cannot reach the set value.
Reason: The internal components of the laser generator have aged or been damaged, such as the pump source and the performance of the laser crystal has declined; the surface of the optical lenses is contaminated or damaged, resulting in loss of laser energy; the laser path is misaligned and fails to focus accurately.
Solution: Contact professionals for maintenance or replacement of faulty components of the laser generator; use special cleaners and dust-free cloths to clean the optical lenses; if the lenses are damaged, replace them immediately; recalibrate the laser optical path to ensure that the beam is accurately focused on the welding area.
The laser cannot emit light, and the equipment does not have laser output.
Reason: The power supply of the laser generator is faulty and cannot provide normal power; the control system's instructions are incorrect or there is an abnormal communication issue with the generator; the internal trigger device of the laser generator is faulty; the protection circuit has been activated.
Solution: Check the power connection and supply voltage of the laser generator, repair or replace the faulty power module; Check the software and hardware of the control system, restart the equipment or reset the parameters; Inspect the trigger device of the laser generator; Check the protection circuits such as the cooling system, eliminate the abnormalities and then reset the protection function.
2.Welding quality-related faults
Gas pores appeared in the weld during the welding process.
Reason: The surface of the welding material is not clean, with impurities such as oil, moisture, and oxide films; the flow rate of the shielding gas is insufficient or the gas is not pure, making it impossible to effectively isolate the air; the laser welding parameters are improperly set.
Solution: Perform strict pre-treatment on the welding materials by means of grinding and cleaning to remove surface impurities; Check the gas supply system for protection, ensuring stable gas flow and meeting the purity standards; Adjust the welding parameters, appropriately reducing the welding speed and adjusting the laser pulse frequency to allow the molten pool sufficient time to expel the gas.
The weld seam has developed cracks.
Reason: The welding materials themselves are highly brittle, or the thermal expansion coefficients of the two materials differ greatly; excessive welding heat input results in a rapid cooling rate of the welding joint, generating significant internal stress; the welding process parameters are unreasonable, such as excessively high laser power or too slow welding speed.
Solution: Select appropriate welding materials; when necessary, use an intermediate transition layer to improve weldability; optimize the welding process, reduce laser power, increase welding speed, and minimize heat input; conduct post-weld heat treatment on the welding joint, such as annealing, to eliminate internal stress.
3.Cooling system failure
Cooling system alarm, indicating excessive temperature
Reasons: Insufficient or deteriorated coolant affects the cooling effect; Faulty cooling water pump causes poor circulation of coolant; Blockage of cooling pipes prevents normal flow of water; Excessive dust on the surface of the radiator reduces the cooling efficiency.
Solution: Immediately replenish or replace the coolant; Check the working condition of the cooling pump, repair or replace the faulty pump; Clean the cooling pipes and clear the blocked areas; Regularly clean the dust on the surface of the radiator to ensure good heat dissipation.
There is water leakage in the cooling system.
Reason: The cooling pipe joints are loose, and the seals are aging and damaged; there are cracks in the cooling water tank or pipes.
Solution: Tighten the loose pipe joints, replace the aged seals; Inspect the cooling water tank and pipes, locate the crack positions, repair them by welding or using special repair agents, and replace the damaged parts if the damage is severe.
--Rayther Laser Camila Wang