Double Wobble Blue Laser Composite Welding Head Widens the Process Window for Thick Materials
Thick section welding is where most laser processes lose their advantage: penetration becomes unstable, spatter rises, and the usable band narrows until only experienced operators can hold it. The HanWei double wobble blue laser composite welding head was developed to remove that constraint. Combining a blue laser with a fiber laser in a two-axis wobble optical system with adjustable spot, the head holds a stable keyhole across a wider range of thickness, speed and fit-up than a fixed spot head.
Why a two-axis wobble extends the process window
A single fixed laser spot concentrates all its energy into a point. On thick plate this produces a narrow, deep keyhole that is sensitive to any change in speed, gap or surface condition, and the weld either lacks fusion or collapses into spatter. The double wobble design moves the spot along two independent axes at high frequency, spreading energy over an adjustable area instead of a point.
- Adjustable wobble width of 0.5-5mm: the same head covers thin cosmetic seams and thick structural passes, so one tool covers a wider product range.
- Two-axis motion: circular, infinity and transverse patterns stir the molten pool in both directions, which slows solidification slightly and lets gas escape before the seam freezes.
- Wider tolerance to speed and focus drift: small deviations in travel speed or standoff no longer push the process out of specification, which matters on long seams and robot cells.
About 70% absorption lowers the working threshold
With an absorption rate around 70%, less laser energy is lost to reflection and more of it reaches the workpiece, so the working threshold is lower. That makes the process more controllable and allows a lower laser power to reach the required penetration than a red light source, which cuts equipment investment and running cost. Less reflected energy also reduces the load on the optics.
Less spatter, better seam formation
Spatter comes from an unstable keyhole ejecting molten metal. A distributed, oscillating spot keeps the keyhole open and the pressure balanced, so the pool behaves predictably.
- No spatter: parts leave the fixture clean, removing a manual cleaning step and the risk of spatter adhering to a finished surface.
- Stable welding: consistent penetration from the first part to the last part of a batch, including long seams and closed-loop robot paths.
- Smooth seam appearance: a fine, uniform ripple without humping or undercut, usually acceptable without post-weld grinding.
- Single-sided welding with double-sided forming: full penetration from one side with a continuous bead on the reverse face, so thick parts do not need to be turned and re-fixtured.
- Better overall seam quality: lower porosity, fewer cracks and reduced distortion thanks to controlled heat input.
Where the head is used
- Copper busbar, laminated foil and battery tab welding in energy storage and new energy packs.
- Thick aluminium and copper pipe, heat exchanger and refrigeration connector welding.
- Handheld guns, robot arms and automated production lines, with CCD monitoring and touch screen parameter control.
Evaluating the process on your own parts
HanWei Laser has manufactured laser welding systems since 2016 and serves customers in Europe, North America, Asia and the Middle East. Wobble width, focus length, gas route, cable length and the blue to fiber power ratio are all configured against sample parts, and every head is assembled, aged and tested before shipment. Send material, thickness and joint drawing, and we return a parameter set plus a welded sample so the process window is verified before you commit to a line.
