How to Evaluate the Welding Performance of a Laser Welding Machine

When purchasing a laser welding machine, it’s not enough to see a clean-looking weld on a demo part. Real-world performance depends on consistency, repeatability, and how well the system handles your specific materials and joint designs. Here’s how to properly assess welding quality.

Start with Visual and Dimensional Checks

A good first step is inspecting the weld seam for cracks, pores, spatter, or discoloration. But go further: measure weld width, penetration depth (via cross-sectioning), and bead uniformity along the entire seam. Even small variations can indicate instability in beam focus, power delivery, or motion control.

Mechanical Testing Matters

For structural applications, visual inspection isn’t sufficient. Perform tensile or shear tests on sample welds to verify strength meets requirements. In battery or medical device manufacturing, peel tests on thin foils are common. Compare results across multiple samples—consistency matters more than a single high-value result.

Check Process Stability Over Time

Run a batch of 30–50 parts under normal production conditions. Does the 50th weld look and perform like the first? Watch for signs of thermal drift, such as gradual changes in melt depth or increased spatter. A reliable laser welding machine should maintain performance without constant manual tuning.

Leverage Built-in Monitoring (If Available)

Modern systems often include coaxial cameras, plasma sensors, or real-time power meters. These tools help detect anomalies like misalignment, contamination, or power drop—before bad parts reach inspection. Ask if the machine logs this data for traceability.

Always test with your materials, surface conditions, and fixturing—not just ideal lab samples. A laser welding machine that works well on clean, flat coupons may struggle with real-world tolerances and oxides. The best evaluation mimics actual production as closely as possible.