LaserHybrid welding

Laser + arc = top-quality welding

LaserHybrid welding unites the advantages of two tried and tested welding methods in a single process: the high energy density and precision of the laser beam with the flexibility and gap-bridging ability of GMAW welding.

This smart combination of processes results in welded joints with deep penetration, a large seam volume, and outstanding mechanical properties. As such, the LaserHybrid process delivers unbeatable productivity, reproducible quality, and high process reliability even when welding challenging materials and geometries.

Whether it’s a single component or large-scale series production, LaserHybrid welding offers a future-proof solution for modern manufacturing requirements across a wide range of industries.

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Advantages of the LaserHybrid welding process

Heat-resistant and dimensionally stable

Controlled, targeted heat input minimizes impacts on strength and hardness, especially in high-strength steels and aluminum alloys. At the same time, distortion and internal stresses are significantly reduced, which improves dimensional accuracy and minimizes rework.

Deep penetration, less filler metal

Penetration with the LaserHybrid process is deep and narrow, making it possible to efficiently join even thicker-walled components (often in a single step) while reducing the amount of filler metal used.

Perfect seam, consistent results

Laser-supported welding creates the conditions for significantly higher welding speeds than with conventional MIG/MAG welding. Depending on the application, speeds of up to 5 m/min are possible—giving you a major productivity edge in series production.

Heat-resistant and dimensionally stable

Controlled, targeted heat input minimizes impacts on strength and hardness, especially in high-strength steels and aluminum alloys. At the same time, distortion and internal stresses are significantly reduced, which improves dimensional accuracy and minimizes rework.

Deep penetration, less filler metal

Penetration with the LaserHybrid process is deep and narrow, making it possible to efficiently join even thicker-walled components (often in a single step) while reducing the amount of filler metal used.

Perfect seam, consistent results

Laser-supported welding creates the conditions for significantly higher welding speeds than with conventional MIG/MAG welding. Depending on the application, speeds of up to 5 m/min are possible—giving you a major productivity edge in series production.

Large process window thanks to LaserHybrid CMT

When you opt for LaserHybrid CMT, you get an even broader range of applications. The CMT process offers optimal control when working with thin sheets, while also delivering impressive performance. It gives you the reliability and stability you need when welding materials of varying thicknesses and complex component geometries.

Excellent seam quality with reproducible results

Thanks to minimal pore formation and spattering (especially when welding with CMT), weld seams are uniform and boast a high-quality appearance with improved mechanical properties. High process stability delivers consistently reproducible results.

How the LaserHybrid welding process works

During LaserHybrid welding, the laser beam and arc act on the workpiece simultaneously. The laser ensures deep energy penetration, while the GMAW arc feeds filler metal and stabilizes the weld seam profile. The laser-induced plasma helps to guide the arc.

Depending on the application, various arc characteristics are used, such as PMC (Pulsed Multi Control) or CMT (Cold Metal Transfer). When combined with CMT in particular, it’s possible to significantly reduce the heat-affected zone, which means that the mechanical properties of the welded joint are largely preserved compared to those of the base material.

Typical applications with LaserHybrid welding

The LaserHybrid welding process stands out thanks to its versatility:

Heavy-gage sheet metal applications, e.g., machine frames for press brakes, shipbuilding, heavy-duty vehicle manufacturing, and steel construction
Thin-sheet metal applications, such as battery housings and battery trays in the e-mobility sector
Pressure vessel and plant construction
Joining high-strength materials, where low heat input and superior component quality are critical

Thanks to its high process stability, LaserHybrid welding is suitable for both automated high-volume production and demanding specialty applications.

Using LaserHybrid welding in frame manufacturing

TRUMPF wanted to bring the production of machine frames weighing several tons back in-house in order to reduce costs, lead times, and dependence on outside suppliers. With a Fronius LaserHybrid robotic welding system, components can now be manufactured efficiently and reliably without the need for energy-intensive spherodizing after welding. The combined laser-MAG process ensures high welding speeds, stable processes, and reduced porosity. At the same time, material usage and component distortion decrease, while productivity and flexibility in manufacturing increase significantly.

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