Common Laser Welding Problems and Solutions

As more and more customers use laser welding machines to replace MIG and TIG welding, many customers who didn't buy machines from us contact us asking why their laser welding machines keep breaking down.

The conversation usually starts like this:

"The laser welding machine is malfunctioning."

In most cases, after our step-by-step inspection… it's actually not broken.

I've been working with laser equipment for several years, and I've found that true machine malfunctions are actually quite rare. More common are seemingly serious minor setting errors.

For example, uneven welds.

Customers will send me photos saying the weld looks strange. Sometimes too wide, sometimes too shallow. They think the laser output is unstable.

But when I ask about their settings, I find they've only changed the material thickness without adjusting the power. Or maybe they welded a little faster that day because production was busy.

Another problem I often see is spatter.

Laser welding should produce less spatter than TIG welding, so people worry when there's more spark. But often, this is because the material surface isn't cleaned properly. Oil or dust can cause problems. Sometimes, simply wiping the surface and testing again solves the problem.

Another issue is "the machine suddenly stopping."

This always sounds serious.

However, modern fiber laser systems are equipped with safety mechanisms. If the temperature is too high, the voltage is unstable, or the cooling system alarms, the machine will automatically shut down. This is to protect the internal components.

Last summer, a customer thought his laser source was broken. Upon inspection, we found the workshop temperature was extremely high and ventilation was poor. After improving ventilation, the machine returned to normal operation.

It's not a big deal.

Many people may think laser welding is like a simple tool—turn it on and forget about it. But it is, after all, industrial equipment, requiring a stable power supply, a cooling system, and a certain amount of maintenance.

Another question I'm frequently asked is about the protective lens burning out too quickly.

Usually, this is related to the flow rate of the protective gas or the working distance. If the nozzle is too close or the gas pressure is too low, the lens will be damaged. Adjusting these parameters will extend the lens's lifespan.

This article is not a technical guide; it's just sharing some observations I've made.

Most laser welding problems are not related to the laser itself, but rather to the environment, parameters, or minor maintenance details.

When an anomaly is detected, it's best to slow down and check for basic issues before immediately assuming the machine is defective.

That's all.