Stainless steel is the most famous material that has been used for a variety of reasons, such as its durability, resistance to all kinds of chemical reactions, and a shiny surface. Manufacturers of products, for instance, those of the kitchenware and the medical field, use them for both the performance and the good looks of their products.

Nevertheless, direct welding of stainless steel is still considered as a problem. The over-usage of heat can result in the steel getting distorted, changing color, and at the same time the joint losing its strength.

That is the reason why pioneering technologies like the Roboto Diamond Galaxy Dop laser welding machine are such a crucial factor in dealing with this material. The various aspects of the system, together with the reasons why stainless steel is suitable for laser welding and the actual advantages, are disclosed in this article.

Why is it necessary to be very careful while welding stainless steel?

Contrary to mild steel, the thermal conductivity of stainless steel is lower. It gets hot in a very short time and solidifies heat very quickly in the immediate area, which is the welding zone.

This may cause:

• Thin metal sheets get bent
• Change in color around the area of the joint
• Functional properties can be degraded due to overheating of the metal
• Although these methods, which include TIG as well as MIG welding, are capable of accomplishing the task, they most of the time require substantial post-processing to bring back the look and the part’s functionality.
• Contrarily, a laser beam is more energy-efficient as it puts energy into its target area in a very concentrated and controlled manner.

This means that the parts will be less deformed, with only a small portion called the heat-affected area, and the welded joints will have a smoother blending.

What are the main components of the Roboto Diamond Galaxy Dop system?

The combination of a fiber laser source, a robotic arm, and a control unit comprises the system at its core.

Every element is responsible for a different function:

• Laser source – generates the beam that melts the metal exactly at the location where the metal is to be, no further than that.
• Robot arm – with multiple axes of movement, it locates the beam at any angle and can follow the shape of a seam that is curved or complex.
• Controller – it saves welding programs and can, at any stage, change the parameters instantly.
• Enclosure and fixtures – are keeping the workpiece stable as well as ensuring the safety of the operator.

Through this synergy, the device can not only find the difficult areas of the joints but also yield the same result even on big and unusually shaped stainless steel parts.

How does it help in modern production?

Today, factory machines are no longer considered separate entities; they are part of the company’s network. The laser welding cells can operate a system interface, record welding parameters, and combine with testing units.

For instance:

• With each and every welding operation, there will be a record of power, speed, and gas flow values.
• In a case where the seam does not meet the standards, the system will thus notify the alert in real-time.
• From different stations, supervisors are able to monitor productivity through the computer without walking across the shop floor.

Such a kind of data-centric operation is Industry 4.0-compatible, where the values of traceability and transparency are equal to that of the speed.

Pragmatic benefits

The use of laser welding is mostly liked because of its quickness; however, the advantages do not stop here:

• Less clean-up – with less spatter, there is a reduction of the grinding and polishing steps.
• Material versatility – can be applied not only to stainless steel but also to aluminum, nickel alloys, and so on.
• Repeatability – once established, a robotic program is able to recreate the same outcomes for every cycle.
• Process documentation – information from every weld can be recorded for audits or future reference.

The automotive, aerospace, and medical equipment industries, along with cycle time, highly emphasize these qualities.

The actual step-by-step workflow

The stages of a typical do seem to go like this:

• A barcode on the part is scanned by the operator.
• An automatic welding recipe that is the most suitable for the part is being loaded.
• Sensors physically confirm the safety of the part in the clamp.
• The robot goes ahead with the welding, and at the same time, the data is being recorded.
• Cameras or probes check the integrity of the joint.
• The information is kept safe and is also linked with the production system.

Welding, which used to be a single mechanical task, has now become a bigger, connected process.

Real-world use cases

The Roboto Diamond Galaxy Dop features the advantages of its performance in the following cases:

• Battery trays for electric vehicles – these trays go through quality control standards that require long, distortion-free seams. 
• Automotive brackets and housings – such devices usually come with a variety of complex angles. 
• Aerospace panels – these panels must be protected from any kind of thermal damage and hence require minimum heat input. 
• Medical instruments – they not only need continuing welds, but also the validations of these welds must meet strict standards. 

Precision, traceability, and repeatability are the cornerstones that each of these applications revolves around.

Things to evaluate before choosing one

The common reasons that manufacturers consider before switching to such a system are:

• Range of part shapes and future designs
• Material Types and Thicknesses
• Procedure requirements for the fixation of the piece
• What information should be gathered and where should that information be stored?
• Training is required for the trainers and the learners

These questions, if answered, will provide the manufacturers with the possibility of foreseeing and thus being able to avoid any surprises, and also ensuring seamless integration.

Handheld vs. robotic solutions

Usage of handheld laser welders is a popular choice that has been made by users for work on repairs and small-scale tasks. In contrast to a portable and easy-to-handle system, a robotic one depends less on operator skill and delivers consistency, traceability, and easy integration into automated production lines.

Although the handheld and robotic systems are not mutually exclusive, on the contrary, they complement each other. However, for precision high-volume stainless work, robotic systems are believed to be more efficient and effective.

The bigger perspective

The use of laser welding in combination with robotics is not solely for quicker welding. It only means that they are building a system that can be a perfect fit into the present-day manufacturing environment, which is mainly driven by data and connectivity.

Anytime stainless steel is involved, the Roboto Diamond Galaxy Dop is always the one to rely on when it comes to striking the right balance between precision, adaptability, and long-term reliability.