In the welding workshop for new energy battery trays, a blue and infrared composite laser beam precisely strikes the aluminum alloy surface, instantly breaking through the oxide film, and creating a stable, mirror-like molten pool. In less than a second, a perfect weld seam—spatter-free, pore-free, and almost invisible—is formed.
Driven by the dual forces of carbon neutrality goals and the booming new energy industry, aluminum alloy has become a favorite in high-end manufacturing. From the lightweight bodies of new energy vehicles to the robust frameworks of aerospace vehicles and the exquisite casings of consumer electronics, aluminum is ubiquitous.
However, its high reflectivity, high thermal conductivity, and stubborn oxide film make welding a "Achilles' heel" that restricts production capacity and quality. Traditional welding methods struggle to balance quality, efficiency, and aesthetics, and the industry is calling for a technological revolution.
Having cultivated the industrial laser field for many years, Fly Laser is directly addressing this challenge, transforming this "tough nut to crack" into a stage to showcase the strength of Chinese intelligent manufacturing with a series of customized, highly intelligent laser welding solutions.
01 Industry Dilemma: The "Welding Pain" Behind Lightweighting
The difficulties in aluminum welding are deeply rooted in the material's inherent properties. First, a laser reflectivity of over 90% means that most of the energy is mercilessly reflected, resulting in low efficiency, and the reflected light can even cause fatal damage to the laser itself.
Secondly, aluminum conducts heat extremely quickly, three times faster than steel. The heat dissipates instantly, leading to an unstable molten pool and poor formation, easily causing defects such as undercutting and collapse.
The most troublesome is the dense aluminum oxide film, whose melting point is far higher than that of the aluminum itself. During welding, fragments of the oxide film can easily be trapped in the molten pool, forming slag inclusions and pores, severely weakening the weld strength and sealing performance. This is an unacceptable risk for battery trays or aerospace components that demand absolute safety.
Traditional processes such as TIG welding can partially solve the problem, but they involve high heat input, severe deformation, and low efficiency, making them unsuitable for modern high-speed, precision, and automated production lines. Aluminum welding urgently needs a comprehensive innovation from principle to process. 02 Technological Breakthrough: Fly Laser's Three Core Weapons
Addressing the aforementioned industry challenges, Fly Laser integrates cutting-edge optical technology and intelligent control to create solutions that directly address pain points.
First, overcoming the energy absorption challenge. Fly laser equipment is equipped with a high-power fiber laser and a unique anti-reflection optical system. Through innovative optical path design and waveform modulation technology, the energy absorption rate of aluminum to the laser is increased from less than 10% to over 85%.
Simultaneously, an optional blue light laser composite module is available. The 450nm blue light has an extremely high absorption rate for aluminum, instantly shattering the oxide layer, ensuring stable welding, reducing welding spatter by 80%, increasing the yield rate to over 99.5%, and completely protecting the laser core from reflected light damage.
Second, achieving precise thermal management. Dual-beam collaborative welding technology is employed: the central high-energy density beam achieves deep penetration welding, while the annular beam preheats or cools, precisely controlling the molten pool temperature gradient. This reduces the heat-affected zone to an astonishing 0.25mm, virtually eliminating workpiece deformation.
Combined with AI vision and OCT online detection systems, the molten pool morphology and weld depth can be monitored in real time, dynamically adjusting power and speed, keeping the porosity rate firmly below 0.3%, and almost eliminating the risk of cracks.
Third, adapting to all-scenario automation. Fly equipment supports continuous, pulsed, and various composite welding modes, and with an intelligent oscillating welding head, it can perfectly handle all grades of materials from 1-series pure aluminum to 7-series high-strength alloys.
The equipment is deeply integrated into automated production lines. Through robotic arms and digital twin technology, the welding process is simulated and optimized in a virtual environment, ultimately achieving efficient, unmanned, and stable mass production of complex components.
03 Practical Parameters: A Process Handbook from Thousands of Verifications
Based on a large number of process experiments, the Fly laser technology team has distilled core welding parameters for different scenarios, providing reliable references for the industry.
Note: Based on the Fly FL-W series equipment, thin-plate welding efficiency is increased by more than 3 times compared to traditional argon arc welding. All parameters can be customized and adjusted according to specific working conditions.
04 Empowering Industries: Excellent Verification from Laboratory to Production Line
Fly Laser's solutions have spanned multiple industries, transforming technological advantages into real competitive advantages for customers.
In the new energy vehicle sector, the aluminum shell welding solution provided to a leading battery manufacturer utilizes vertical welding technology, significantly reducing the number of welding points on square battery shells, lowering the risk of side leakage by **80%**, and matching the welding speed to the high-speed production line cycle. In all-aluminum body welding, it replaces a large number of traditional rivets, achieving significant weight reduction and helping customers shorten the return on investment cycle of their production lines.
In the aerospace field, Fly Laser welded high-strength aluminum-magnesium alloy frames for a drone manufacturer. Using precision pulse welding, the weld seam non-destructive testing pass rate was greatly improved, and the workpiece deformation was controlled within 0.02mm, fully meeting the stringent aerospace standards.
In the consumer electronics field, for the welding of ultra-thin aluminum alloy heat sinks (0.8mm), it achieved splash-free and discoloration-free precision processing. The weld seam requires no secondary grinding, increasing production efficiency by 5 times, perfectly matching the 3C industry's dual pursuit of aesthetics and efficiency.
05 Comprehensive Protection: One-Stop Service Beyond Equipment
Fly Laser understands that delivering a piece of equipment is only the beginning of a partnership. Therefore, we have built a service system covering the entire product lifecycle.
In the pre-sales stage, our technical engineers conduct in-depth research on the workpiece material, structure, and cycle time at the customer's site, providing customized process solutions and feasibility verification.
In the sales stage, we provide professional equipment operation and maintenance training, and can provide dedicated anti-deformation fixtures and efficient cooling systems to ensure the equipment performs optimally.
In the after-sales stage, we promise a 24-hour online response and, relying on more than 30 service outlets nationwide, guarantee on-site service within 48 hours. Core equipment components are covered by a warranty of up to 2 years, giving customers peace of mind.
Fly Laser's equipment is operating stably on a new energy vehicle battery tray production line. The workshop supervisor pointed to the flawlessly smooth weld seams and said, "Porosity and cracking issues are basically a thing of the past. The yield rate is consistently above 99.5%, a figure we couldn't have imagined before."
As lightweighting becomes a competitive arena in global manufacturing, welding quality is the critical factor determining success or failure. Fly Laser, with its solid technological innovation, has transformed aluminum welding from a manufacturing bottleneck into a quality advantage.
From micron-level precision points to structural seams several meters long, Fly Laser is using beams of "intelligent light" to redefine the possibilities of connection, working with partners to pursue a lighter, stronger, and more efficient manufacturing future.
Making aluminum welding no longer an art of compromise.
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