Welding aluminum, steel & brass with Wattsan laser machines: practical tips & setup advice

Contents:

Laser welding is an effective method of joining various metals such as aluminum, stainless steel, carbon steel and brass. With the right equipment and the right parameter settings, it ensures clean, durable seams with minimal deformation. In this article, we will look at the basics of laser welding on Wattsan machines: from choosing the right seam shape to choosing a protective gas and setting key parameters.

Seam shape: the foundation of a strong weld

Wattsan laser welding machines are equipped with Relfar laser guns. Relfar laser guns feature a lightweight design, easy handling, and excellent welding results.

Two main types of Wattsan devices are used for welding:

• Wattsan G1 models are equipped with one movable mirror that creates a linear seam.
• Wattsan G2 models have two mirrors, which allows you to use a variety of seam shapes such as triangle, circle, hourglass and figure eight.

Each seam shape serves a specific purpose:

• Linear seam: best suited for carbon and stainless steel. It provides fast and clear welding, but is not suitable for metals such as aluminum or brass due to their rapid cooling, which can lead to cracks or poor adhesion.
• Triangle and circle: suitable for all metals. These molds provide better heat distribution, uniform penetration on both sides, and slower cooling, reducing the risk of weld failure.
• Hourglass and figure eight: recommended for thick or high-load materials. These molds improve the healing, penetration, and overall durability of the weld.

Choosing the right seam shape is crucial to prevent defects such as cracks, porosity, or insufficient penetration.

The role of protective gas

The use of protective gas during laser welding is not necessary — it is necessary to achieve high-quality results. The protective gas helps:

• Prevent oxidation of the welding area
• Reduce splashing and the risk of porous seams
• Improve the quality and appearance of the seam
• Eliminates the shielding effect of metal vapors, increasing laser efficiency
• Protects optical components and cools the nozzle

This is how different gases interact with different metals.:

• Nitrogen (N₂): suitable for stainless steel, but not recommended for aluminum or carbon steel due to possible chemical reactions.
• Argon (Ar): a universal choice. It is compatible with all metals to be welded.
• Helium (He): provides excellent welding quality, but is rarely used due to the high cost.

In most cases, argon provides the best balance between performance and availability.

Using filler wire

When working with parts that have large gaps or require deeper seams, a filler wire is required. Wattsan laser welding machines support both single and double automatic wire feed.

Important considerations when using wire:

• The composition of the wire must match or be close to the base metal.
• Always clean the wire before use to avoid oxidation and welding defects.
• The diameter of the wire must match the thickness of the material. Use the reference table to determine the correct ratio.

This ensures smooth feeding, uniform melting and a strong connection during welding.

In this table you can see the ratio between the thickness of the material and the diameter of the wire. 

	THIN	MEDIUM	THICK
Aluminum	1,0-1,6 mm(alum up to 1,5 mm)	1,6-2,0 mm(alum from 1,5 up to 3 mm)	2,0-3,0 mm(alum from 3 mm)
Brass	0,8-1,0 mm(brass up to 1,5 mm)	1,0-1,2 mm(brass from 1,5 up to 3 mm)	1,2-1,6 mm(brass from 3 mm)
Stainless	0,8-1,2 mm(stain up to 1,5 mm)	1,2-1,6 mm(stain from 1,5 up to 3 mm)	1,6-2,4 mm(stain from 3 mm)
Carbon steel	0,8-1,0 mm(carbon up to 3 mm)	1,0-1,2 mm(carbon from 3 up to 6 mm)	1,2-1,6 mm(carbon from 6 mm)

Welding parameters: power, speed, and focus

Achieving optimal welding results depends on carefully selected parameters.:

• Power: welding thicker and harder metals requires higher laser power.
• Speed: if the welding speed is too high, the seam may turn out to be incorrect. If welding is too slow, the metal may overheat or deform.
• Focus: in most cases, the focus point should be slightly above the surface of the material. This improves penetration and reduces surface burn.

Wattsan machines are equipped with a Ruida controller with a user-friendly touch interface. The control panel allows you to:

• Saving and reusing preset settings
• Adjustment of seam shape and wire feed rate
• Fast switching between welding modes

This simplifies the workflow and ensures consistent results across multiple projects.

Final checklist & conclusion

Welding metals on a Wattsan machine is simple — provided the settings are correct and the recommendations are followed. Here is a brief description of the key points:

Seam shapes:

• Linear – for carbon and stainless steel
• Triangular and round – for all metals.
• Hourglass and figure eight – for thick materials

Protective gas:

• Argon is universal
• Helium is highly efficient, but expensive
• Nitrogen – suitable only for stainless steel

Filler wire:

• Corresponds to the composition of the metal
• Clean the wire before use
• Use a diameter that matches the thickness of the material.

Parameters:

• Power and speed adjustment depending on the material
• Focusing slightly above the surface
• Use the Ruida controls to manage and save settings.

When properly configured, Wattsan machines enable professional-level welding in a wide range of materials and applications, and they provide the necessary power, control, and precision.

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