Aluminum welding reimagined: Handheld laser beam welding boosts productivity and quality

Handheld laser beam welding opens up new possibilities in aluminum fabrication. Lower heat input, high welding speeds, and reduced post-processing requirements make the technology an attractive option for modern manufacturing companies. With its modular laser welding cell, Bernd Siegmund GmbH offers a flexible protective enclosure solution for handheld laser welding and laser cleaning.

Aluminum has become indispensable in modern vehicle manufacturing, mechanical engineering, and plant construction. Its low weight, corrosion resistance, and versatile mechanical properties make it a highly sought-after material for numerous industrial applications. At the same time, processing aluminum places high demands on precision, process control, and heat management.

In welding applications in particular, controlled heat input and minimal distortion are crucial. While conventional TIG welding can produce high-quality results, it often involves comparatively long processing times and requires considerable experience and manual precision. Handheld laser beam welding offers an interesting alternative.

Lower Heat Input, Greater Efficiency

Thanks to the high energy density of the laser beam, handheld laser beam welding can produce weld seams at high speeds. Compared with conventional arc welding processes, the amount of heat introduced into the workpiece can be lower. This is particularly important when welding aluminum, as it can help reduce the risk of distortion and thermally induced stresses.

There are also potential advantages in terms of weld seam quality and post-processing. Depending on the component geometry, material, welding task, and process parameters, narrow and consistent weld seams with an attractive appearance can be achieved. As a result, the amount of subsequent finishing work can be reduced in many applications.

Potential Benefits of Handheld Laser Beam Welding:

• High welding speeds compared with conventional arc welding processes
• Reduced heat input and therefore potentially less component distortion
• Consistent, visually high-quality weld seams
• Reduced post-processing requirements in suitable applications
• Efficient processing of longer weld seams
• Attractive economic potential, even for small and medium-sized production runs

The actual results always depend on the specific application, material thickness, material combination, joint geometry, and process parameters used.

Safety When Working with Reflective Materials

While laser technology offers significant advantages, it also places greater demands on occupational safety. In handheld laser welding, direct laser radiation as well as potential reflections and scattered radiation must be reliably controlled. This is particularly important when working with reflective materials such as aluminum.

A suitable protective enclosure is therefore an essential component of a safe laser system. It should protect the operator and other people in the surrounding area from hazardous laser radiation while still providing practical access to the working area. The enclosure must be designed to suit the laser source used, including its wavelength and power, as well as the specific application.

Siegmund’s Modular Laser Welding Cell

With its modular laser welding cell, Bernd Siegmund GmbH offers a protective enclosure solution for handheld laser welding and laser cleaning applications. The cell is designed for a wavelength range of 940 to 1090 nm and laser power levels of up to 4 kW.

Pre-assembled side panels enable rapid commissioning and help reduce installation effort. According to the manufacturer, the protective enclosure is CE-compliant and certified in accordance with DIN EN 60825-4.

One of the key advantages of the solution is its modular design. The laser welding cell can be adapted to different spatial conditions and production requirements and expanded as needed. This makes it suitable both for integration into existing working environments and for planning new laser workstations.

An optional safety package featuring door monitoring, an emergency stop function, signal technology, and a control cabinet provides additional equipment to meet the requirements of the respective application.

For enhanced protection, Siegmund recommends using a fully enclosed roof. This reduces the risk of laser radiation escaping upward and also provides a connection point for a welding fume extraction system.

Efficient Aluminum Processing with the Right Safety Concept

Handheld laser beam welding offers considerable potential for aluminum fabrication, including high productivity, controlled heat input, and the possibility of reducing post-processing requirements. To make safe use of these advantages in everyday industrial production, companies need not only suitable laser technology but also a protective solution tailored to the process.

With its modular laser welding cell, Bernd Siegmund GmbH supports companies in designing flexible laser workstations and integrating safety and ergonomic requirements into their production planning.

Further information about the modular laser welding cell and Siegmund solutions is available at: www.siegmund.com/lasercell-info

General Information about Bernd Siegmund GmbH:

Bernd Siegmund GmbH is an owner-managed family business with a 35-year company history. As the global market leader in welding and clamping tables, the company operates five locations across Europe and has an international sales network spanning more than 60 countries.

Our products stand for maximum functionality and exclusive design and are used across virtually all industries. Two of many notable examples include the use of Siegmund welding tables in rocket construction by the aerospace company SpaceX and for repair work at the White House in Washington, D.C.

Siegmund welding and clamping table systems are based on a flexible modular concept. In addition to mechanical engineering, plant engineering, metal fabrication, and vehicle manufacturing, they are particularly well suited to prototype construction and series production, both with and without robotic integration.

Combined with our extensive range of accessories, we offer a simple, efficient, and time-saving solution for virtually every challenge.