Introduction:
You might be familiar with laser welding. It uses high-power light beams to join separate metals. The laser beam passes through the laser welding gun and finally hits the material. This gun is also known as a laser welding nozzle.
Laser welding can be of various types: with and without filler, handheld, or fixed. Each type has its unique benefits and applications. The laser welding nozzle also varies with these types. You must choose the right one to get the best result. This necessitates to know more about laser welding nozzles and their types.
This article mainly talks about laser welding nozzles. You will get valuable information about their types, unique uses, and popularity. You will also learn how to choose a suitable laser welding nozzle for your job. This guide can help importers, suppliers, and retail sellers understand this product better.
What is a Laser Welding Nozzle?
A laser welding nozzle, also known as a laser welding gun, controls and shapes the laser beam. It has some crucial jobs in the laser welding operation.
(1) A laser welding nozzle directs the laser beam onto the workpiece. The nozzle ensures perfect welding of the laser beam. The focused laser beam can smoothly create concentrated HZ for welding. This heat zone generally produces the weld seam and joins two metal parts.
(2) This nozzle protects and stabilizes the laser beam’s path. Think about a handheld laser welding machine. You have to move it frequently. If you don’t have the nozzle, you will find it challenging to focus the laser on the workpiece, right? Because you need to know the exact focus point to create the HZ. Besides, human hands can not be steady, so you will find it challenging to focus on the object every time. So, a laser welding nozzle shapes the beam and helps control the intensity.
(4) The laser welding nozzle also holds the filler. This laser part plays a crucial role in that laser welding machine that needs filler. It perfectly points the filler at the welding spot.
Laser welding is a trendy method in many industries. People like to use it in automotive, aerospace, electronics, and many more industries.
How Does Handheld Laser Welding Nozzle Work?
Working with a handheld laser welding machine requires fundamental expertise. Safety is also a concern. A laser beam can harm your eyes, so wear safety glasses.
First, you can take the laser welding nozzle to the welding site. The nozzle is connected to the laser source. It may also have the filler material linked to the wire feeder. You can find the wire feeder device inside the laser source cabinet.
Next, when you activate the laser, it emits a highly concentrated beam of light. Flathead beams are widely used for welding. However, the concentrated laser beam travels through the nozzle. Finally, it hits the metal surface.
The nozzle design generally helps direct the laser beam. As you move the nozzle along the joint, the melted metal flows together and creates a strong bond. In some cases, filler materials help a lot here. The material is fed through the nozzle and melts to fill gaps. However, filler material is usually unnecessary if the gap is not too big. The use of filler can improve joint tolerance. You will learn more about it in the following section.
Types of Laser Welding Nozzles Based on the Use of Filler Materials
Filler materials are extra items used in the welding process. They mainly help fill spaces between separate metal parts. Their main goal is to improve strength and ensure better bonding. We can classify laser welding nozzles into two main types based on these materials.
Type #1 Laser Welding Nozzles Without Filler
As the name suggests, these laser welding nozzles generally do not need fillers. They are great for jobs that require extra materials. The nozzle focuses the laser beam directly onto the object. Then, it melts the edges of the two separate pieces and joins them together. Since the base material is the same, they offer high strength when joined.
Benefits
- Clean and precise welds
- There is no need for additional material, reducing operation costs.
- These laser welding nozzles are suitable for delicate components and small parts.
Limitations
- Not suitable for thicker materials
- It may not offer high strength.
Type #2 Laser Welding Nozzles with Fillers
These Laser welding Nozzles need fillers for the job. You can see a groove on top of the head to facilitate the passes of filler wire. These nozzles typically fill the gap between the two separate materials. As a result, you can have more strength for thicker metals. In most cases, brass, bronze, copper, nickel alloy, or silver are used as filler wire. The popular models are AS, BS, CS, DS, ES, and FS.
| Nozzle Type | Filler Wire Size | Main Function |
| AS | 0.8, 1.0, 1.2 mm | Flat, inner, and outer angle |
| BS | 1.6 mm | Flat, inner, and outer angle |
| CS | 0.8, 1.0, and 1.2 mm | Outer angle |
| DS | 0.8, 1.0, and 1.2 mm | Flat, inner, and outer angle |
| ES | 0.8, 1.0, 1.2 mm | Outer angle |
| FS | 1.6 mm | Outer angle |
Benefits
- These laser welding nozzles can fill gaps in the joint.
- They are great for irregular joints as well.
- Filler welding offers increased strength.
- Highly suitable for thicker materials and complex joint
Limitations
- Not suitable for delicate components
- More expensive
- Creates spatter that needs additional weld finishing
Types of Laser Welding Nozzles Based on Specification
Laser welding nozzles come in various types. The different types mainly depend on unique specifications. (1) The type of welding tasks. (2) Need precision. (3) Power consumption. (4) Special features. Therefore, choosing the right type depends on the task at hand. In general, the laser welding nozzle can be of 4 types.
Type #1 Standard Nozzle
These laser welding nozzles are the most commonly used ones. They have several standard sizes from Type A to Type J. They are versatile and can handle many tasks. Standard nozzles are ideal for general-purpose welding. They are easy to find and replace. They all have M10 threads, which means you can easily install them.
Type #2 Precision Nozzle
As the name implies, these laser welding nozzles are made for precision jobs. They are perfect for delicate component welding.
You may often find these laser welding nozzles in electronics or medical industries. They offer better control over the welding process and produce clean welds.
Type #3 High-power Nozzle
These laser welding nozzles are made for high-energy laser welding jobs. They often come with filler materials to handle thick metals. These nozzles are used for heavy-duty applications. The type A laser welding nozzle is the best example of this kind.
Type #4 Specialty Nozzle
Finally, specialty laser welding nozzles are made for unique purposes. For example, confined spaces or plastic welding may need particular nozzle types. These nozzles generally come with a custom design. Using these nozzles, you can work with more complex welding jobs.
How to Choose the Right Laser Welding Nozzle for Your Application
When choosing different laser welding nozzles, compare their specs to your project needs. There are six points to consider here.
Factor #1 Type of Your Welding Job
The type of welding job you do heavily depends on the type of laser welding nozzle you use. For instance, welding thin metal sheets requires a different kind of nozzle than welding thick metals.
Factor #2 Material Being Welded
Different metals need different types of nozzles. So, you must ensure your laser welding nozzle is compatible with your working material. Some nozzles are designed to handle thermal or electrical conductivity.
Factor #3 Needed Precision
Precision is especially necessary for delicate components. Some nozzles are designed to deliver fine control over the welding process. So, before you choose a nozzle, evaluate your application first.
Factor #4 Power Consumption Rate
Next, you must check the output power of your handheld laser welder. High-power nozzles are designed to withstand higher energy levels.
Factor #5 Cost Alternatives
Cheap products cannot offer long-lasting services, and expensive items don’t always mean good quality. So, you must check the manufacturer and their customer reviews for the product.
Factor #6 Compatibility with the main portable laser welding machine
Finally, ensure that your device’s chosen laser welding nozzle is compatible. The M10 thread is an international standard for all laser welding machines. However, if you need a custom-sized nozzle, you can get one from a custom manufacturer like ZL Tech.
Summary
A laser welding nozzle is a crucial part of a laser welding machine. It comes in various shapes and types. The following table lists the standard sizes for laser welding nozzles. You may also find other standards, but the following ones are the most common.
| Nozzle Type | Height | Thread | Filler Wire | Remarks |
| Type A | 40 mm | M10 | 1mm or 1.5 mm | Auto wiring |
| Type B | 40 mm | M10 | Not Applicable | Plane Angle |
| Type C | 40 mm | M10 | Not Applicable | Inner corner |
| Type D | 40 mm | M10 | Not Applicable | Outer corner |
| Type E | 40 mm | M10 | Not Applicable | Cutting, Welding |
| Type F | 25 mm | M10 | Not Applicable | Inner corner |
| Type G | 25 mm | M10 | Not Applicable | Outer corner |
| Type H | 25 mm | M10 | Not Applicable | Plane Angle |
| Type I | 25 mm | M10 | 1.2 mm filler | Auto wiring |
| Type J | 25 mm | M10 | Not Applicable | Cutting, welding |