In the field of precision joining in manufacturing, welding dissimilar materials like stainless steel and copper has always been a notoriously difficult challenge. The two materials have significantly different coefficients of thermal expansion, and copper exhibits pronounced high reflectivity. Traditional welding processes often suffer from problems such as porosity cracks, insufficient weld strength, and severe deformation, severely restricting product performance and production efficiency.
Fly Laser has been deeply involved in laser welding technology for many years. Addressing the pain points of welding stainless steel and copper, it has independently developed a dedicated welding solution. Using blue laser technology as its core, it overcomes the challenges of material property differences, providing efficient, precise, and stable welding options for industries such as new energy, refrigeration, 3C (computers, communications, and consumer electronics), and automotive parts.
I. Addressing the Pain Points of Traditional Copper-Steel Welding: Fly Laser Solves Them One by One
The physical and chemical properties of stainless steel and copper differ significantly. Traditional processes such as argon arc welding and brazing struggle to balance connection quality and production efficiency. The main pain points are concentrated in three areas:
Copper's absorption rate of traditional infrared lasers is less than 5%, resulting in significant energy waste and problems such as incomplete penetration and excessive spatter.
The thermal conductivity and coefficient of thermal expansion of the two materials differ by 3-5 times, leading to stress concentration during welding and making the weld prone to cracking and deformation.
Traditional processes require complex pretreatment or filler wire operations, resulting in cumbersome procedures, large fluctuations in yield during mass production, and high maintenance costs.
Fly Laser has specifically overcome these technical bottlenecks, upgrading copper-steel welding from "barely meeting standards" to "stable and excellent," completely resolving industry pain points.
II. Fly Laser's Core Advantages in Copper-Steel Welding: Redefining Precision Connections
1. Blue Laser Core Technology Overcomes High Reflectivity Challenges
Utilizing 450nm wavelength blue lasers, compared to traditional infrared lasers, the absorption rate of copper is increased to over 85%, with simultaneous optimization of stainless steel absorption efficiency. 1. Energy is precisely focused on the weld area, eliminating the need for high-temperature preheating and avoiding deformation and elemental loss caused by excessive material melting, achieving "low-temperature, high-efficiency" welding.
2. Exceptionally high weld quality, far exceeding standards.
No spatter, no porosity; the weld is smooth and mirror-like, requiring no subsequent grinding; both appearance and strength meet standards.
The weld's tensile strength can reach over 90% of the base material; corrosion resistance is 2-3 times higher than traditional processes; leakage rate is controlled below 0.001%.
The heat-affected zone is reduced to within 0.1mm; workpiece deformation is ≤0.03mm, perfectly suited for the welding requirements of precision components.
3. Intelligent Process Enhancement for Optimized Efficiency and Costs
Equipped with a dynamic power adjustment system, it adapts to changes in material properties during welding in real time, automatically compensating for energy deviations, maintaining a stable yield rate of **99.99%**.
Supporting automated integration, and coupled with an intelligent weld seam tracking system, it achieves second-level single-point welding, increasing production efficiency by 3-5 times compared to traditional processes.
Eliminating the need for filler wire and simplifying pre-processing, it reduces consumable costs by 40% and labor costs by 60%, significantly improving enterprise profitability.
4. Flexible Adaptability to Multiple Scenarios, Meeting Diverse Needs
Whether it's connecting thin-walled stainless steel to copper busbars, butt welding copper pipes to stainless steel flanges, or micro-welding precision electronic components, Fly Laser can customize process parameters according to workpiece size and thickness (0.1-5mm). It supports various welding methods such as continuous welding, spot welding, and sealing welding, and is compatible with various material combinations including pure copper, brass, and 304/316 stainless steel.
III. Extensive Applications Across Multiple Industries, Demonstrating Technological Strength
Fly Laser's copper-steel welding solutions have been widely implemented in major core industries, becoming the preferred partner for many leading companies:
New Energy Industry: Welding copper busbars to stainless steel terminals in power batteries, meeting high-current transmission requirements. Welding consistency ensures battery pack stability, serving numerous new energy vehicle manufacturers and battery manufacturers;
Refrigeration Industry: Welding copper pipes to stainless steel heat exchangers in air conditioners and refrigerators, providing excellent sealing performance, reducing refrigerant leakage risks, and contributing to a 15% improvement in product energy efficiency;
3C Electronics Industry: Welding copper heat sinks to stainless steel brackets in mobile phones and laptops. High-precision welding ensures efficient heat dissipation, adapting to the trend of miniaturization and thinning of electronic products;
Automotive Parts Industry: Copper-steel connections in automotive sensors and fuel systems, vibration-resistant and anti-aging, meeting the stringent reliability standards of the automotive industry.
IV. Case Study: An Efficiency Revolution at a New Energy Company
A leading new energy battery company previously used argon arc welding to weld battery copper busbars to stainless steel terminals, resulting in large deformation, a yield rate of only 85%, and a daily production capacity of less than 500 units per employee.
The introduction of Fly Laser's copper-steel welding equipment has achieved three major breakthroughs: yield rate increased to 99.98%, completely eliminating rework caused by welding defects; workpiece deformation is controlled within 0.02mm, eliminating the need for subsequent correction processes; and the automated production line's daily output per employee increased to 2000 pieces, reducing overall production costs by 35% and quickly recovering equipment investment costs.
V. Fly Laser: More Than Just Welding, Empowering Future
Fly Laser's mission is to "drive industrial upgrading through technological innovation." In addition to providing high-performance welding equipment, it also provides customers with full-process service support:
Free on-site survey of working conditions, customized welding solutions and process parameter libraries;
Professional technical team for on-site installation and commissioning, providing one-on-one operation training;
7×24-hour after-sales response, regular equipment inspections and technical upgrades to ensure uninterrupted production.
From laboratory research and development to large-scale production, Feilai Laser uses stable technology, reliable quality, and attentive service to help enterprises break through copper-steel welding bottlenecks and seize market competitive opportunities.
If your company is facing challenges in welding dissimilar materials like copper and steel, or if you'd like to further improve production efficiency and reduce costs, please leave a message and contact Fly Laser's technical consultant. We will provide you with free welding samples, process demonstrations, and solution quotations, allowing laser technology to inject new momentum into your business growth!
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