In manufacturing welding processes, material properties directly determine weld quality. When purchasing a laser welding machine, most companies first ask: “Can it weld my material?” Thanks to its concentrated energy, small heat-affected zone and high precision, laser welding is far more versatile than conventional processes. It handles common metals and many exotic materials. Below is a comprehensive guide to what laser welding can join, how it performs and where it is used—helping you decide quickly whether it fits your production needs.
Core materials – metals are the mainstay, covering almost every industrial scene
Laser welding excels with metals. Carbon steels, stainless steels, aluminium alloys, copper alloys and even high-temperature alloys can be welded with high quality.
Carbon & low-alloy steels: Low welding difficulty. Laser energy penetrates fast, giving strong, cosmetically appealing joints. Suitable for 0.5–10 mm thickness, widely used in rail-car bodies and battery-rack frames.
Stainless steels: Virtually no oxidation discolouration; smooth, clean welds; minimal distortion. Types 304, 316, etc. are standard. Typical parts: EV-battery enclosures, aerospace precision components.
Aluminium alloys: High thermal conductivity and porosity risk are overcome by tuning pulse shape and using filler wire. Stable joints in 0.8–8 mm sheet. Core process for EV chassis parts and rail interior panels.
Copper alloys: High reflectivity and conductivity are tackled with high-power density. Copper-to-copper and copper-to-aluminium dissimilar joints are routine for battery tabs and electrical connectors.
Titanium / nickel-base super-alloys: These demand minimal heat input to avoid property loss. Laser’s tiny HAZ preserves strength and corrosion resistance. Used in aero-engine and medical-device manufacture.
Extended materials – non-metals & dissimilar joints for special needs
Beyond metals, laser welding is already mature for thermoplastics and dissimilar-metal combinations.
Non-metals: Mainly thermoplastics (PP, PC, ABS). Laser melts the interface, creating strong, odour-free seams for electronic housings and automotive interiors. Premium systems even braze ceramics to metals for precision sensors.
Dissimilar metals: Steel–Al, Cu–Al, Ti–steel, etc. Laser’s precise heat control suppresses brittle intermetallics. Common in EV battery modules (Cu tabs to Al busbars) and lightweight auto parts, combining the best properties of each metal.
Why laser can “weld more and weld better”
Energy focused & controllable: Spot size 0.1–1 mm; power density breaks through high conductivity/reflectivity without excess melting.
Small HAZ: Heat stays in the joint, limiting distortion and cracking—ideal for thin or precision parts. High speed: 2–5× faster than arc welding, reducing oxidation and alloy burn-off. Flexible: Power, pulse frequency and travel speed are instantly adjustable for different thicknesses or materials—no tooling change-over.
Real-world industry cases
Rail transport: Stainless and aluminium body frames and interior panels, >99.8 % weld acceptance rate.
Energy storage: Copper/aluminium tabs sealed into steel or stainless enclosures, meeting strict conductivity and hermeticity requirements. Aerospace: Titanium and nickel-base alloy engine and structural parts welded with zero property degradation. Electronics: Micro-joints on copper connectors and plastic housings, boosting reliability in miniaturised assemblies.
Three checkpoints when choosing a laser welder for your material
State material type & thickness: Tell the supplier the exact alloy (e.g. 6061 Al, 304 SS) and thickness so they can match laser power (1–3 kW for thin sheet, 4–10 kW for thick section).
Clarify dissimilar-metal needs: If you must join steel–aluminium or copper–aluminium, insist on pulsed-mode capability and a special welding head.
Demand process support: A quality vendor supplies parameter development, sample welding trials and long-term service, preventing poor settings from ruining production.
Whether you weld everyday carbon or stainless steels, difficult aluminium or copper alloys, or need dissimilar-metal and non-metal joints, PDKJ laser welders deliver.
As a specialist manufacturer, we offer high-power stable laser sources with precision control systems. Parameters are optimised for each material, guaranteeing strong, good-looking seams. Our machines (including robotic versions) serve rail, energy-storage, aerospace and electronics sectors. Free material trials, parameter tuning guidance and lifetime after-sales support are standard. Wondering if your material can be welded or need a custom process? Contact PDKJ— we solve every welding challenge and boost your productivity and quality.
If you have welding machine requirements, please contact Ms. Zhao
Founded in 2006, PDKJ is a professional supplier of welding automation solutions. The company has passed the ISO9001 international quality management system certification, has more than 90 officially authorized and applied national patents, and a number of core technologies in the welding field fill the technical gap at home and abroad. It is a national high-tech enterprise.
