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Products in the electronics industry are evolving at an astonishing pace. From the early 3G and 4G technologies to today’s 5G communication, popular foldable screens, lightweight and compact wearable devices, and 3C consumer electronics—all these require laser welding. Currently, laser welding technology and equipment are steadily maturing, with various laser applications being developed to meet different product needs, such as laser ball-joining soldering machines, laser wire-bonding soldering machines, and laser paste-soldering machines. The market is now gradually shifting toward laser welding.

Laser welding is a laser-based soldering technique that uses a laser as the heat source to heat the soldering pads, melt solder wires or solder paste, and complete the soldering process. The primary feature of laser welding is its ability to rapidly heat localized or tiny areas with high laser energy, thereby achieving precise soldering. Compared with traditional soldering methods such as hot-bar soldering and soldering iron soldering, laser soldering machines offer advantages including high processing accuracy, high efficiency, high yield rate, and low production costs. They come equipped with specialized soldering software that is easy to operate and quick to use; their modular design allows for flexible combinations and configurations, and they boast a high degree of automation.

Laser soldering machines help companies save on production costs.

1. Laser soldering machines virtually require no consumables. As is well known, traditional soldering iron tips incur significant annual costs for heating core consumables, whereas laser soldering machines essentially have no consumables at all.

2. Solder waste. Every time before and after soldering, the soldering iron needs to be cleaned of residual solder on its tip; in contrast, laser soldering machines don't require such cleaning, saving a significant amount of money each year.

3. Technical and Time Costs: Each time the soldering tip is replaced, the soldering iron must be cooled down beforehand, and after each replacement, the position needs to be recalibrated. In particular, the heating element requires a skilled technician for replacement; once replaced, it needs to be repositioned, which wastes considerable time and calls for specialized technical personnel.

As can be seen from the three points above, although the purchase cost of an automatic laser soldering machine is higher than that of a conventional soldering machine, in the long-term production process at a factory, the laser soldering machine can help companies significantly reduce both usage costs and production costs.

Compared to laser cutting and laser marking, laser welding has a relatively shorter development time but presents greater process challenges. Among these challenges, the factors affecting the quality of spot welding in laser soldering machines have become key concerns for customers when purchasing laser welding equipment. The primary factors include welding current and pulse duration, electrode pressure, and shunting effects.

1. Welding current and energizing time: Depending on the magnitude of the welding current and the duration of energization, spot welding can be categorized into “hard specifications” and “soft specifications.” In a short period with high current, the specification is referred to as a “hard specification,” which offers advantages such as high productivity, long electrode life, and minimal deformation of the workpiece. It is particularly suitable for welding metals with good thermal conductivity. On the other hand, specifications involving low current over an extended period are called “soft specifications”; they have lower productivity but are well-suited for welding metals that tend to harden during the welding process.

2. Electrode Pressure. In spot welding, the pressure exerted by the electrodes on the workpieces is referred to as electrode pressure. It is essential to select the electrode pressure appropriately. When the pressure is relatively high, shrinkage porosity and shrinkage cavities that may occur during the solidification of the weld nugget can be eliminated. However, this also leads to a reduction in bonding resistance and current density, resulting in insufficient heating of the workpieces, a smaller weld nugget diameter, and a decrease in the strength of the weld points. The magnitude of the electrode pressure can be determined based on the following factors: (1) The material of the workpieces. The higher the high-temperature strength of the material, the greater the required electrode pressure. Therefore, when welding stainless steel and heat-resistant steel, the electrode pressure should be higher than that used for welding low-carbon steel. (2) Welding parameters. The harder the welding specifications, the greater the electrode pressure required.

3. Shunt Current. During spot welding, the current that flows externally from the main welding circuit is referred to as shunt current. A reduction in the shunt current flowing through the welding zone leads to insufficient heating, significantly weakening the weld joint strength and compromising welding quality.