Reasons And Preventive Measures for Virtual Welding in Laser Welding

The main reasons for virtual welding in laser welding process include the following:

1. Insufficient welding temperature: If the laser power is too low or the welding time is too short, the solder cannot fully melt and wet the surface of the workpiece, which can easily lead to virtual welding. ‌

2. Insufficient cleanliness of the solder surface: Impurities such as oil stains and oxide layers on the solder surface can hinder the adhesion of solder and lead to virtual soldering. ‌

3. Poor quality of soldering materials: Poor purity, melting point, and other properties of soldering materials, or uneven distribution and insufficient content of soldering flux, can all affect the soldering quality.

4. Improper temperature of soldering iron tip: Excessive or insufficient temperature of soldering iron tip can affect the welding quality and lead to virtual soldering. ‌

5. Poor control of welding time: Welding time that is too long or too short can affect the melting and spreading of solder, leading to virtual soldering.

6. Loose components during welding: If the welded components become loose during welding, it can cause the solder to not fully fill the solder joints, resulting in virtual soldering.

7. Component pin oxidation: Component pins will gradually oxidize during use, causing an increase in contact resistance with solder and forming virtual soldering.

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The measures to prevent virtual welding in laser welding include:

1. Adjust laser welding parameters: increase laser power or extend welding time appropriately, but be careful to avoid damaging the welded parts due to high temperature. For example, after virtual soldering occurs, the laser power can be increased by 5% -10% each time, while observing the status of the solder joint until the virtual soldering problem is resolved.

2. Clean the surface of the welding piece: Before welding, use a suitable cleaning agent (such as alcohol, specialized metal cleaner, etc.) to clean the surface of the welding piece, remove oil stains and oxide layers. For metals with oxide layers, mechanical polishing or chemical acid washing can be used for treatment.

3. Check the quality of soldering materials: Ensure the use of qualified soldering wires and that the flux content and distribution meet the requirements. If the soldering flux is insufficient, it can be considered to replace the solder wire or add soldering flux appropriately during the soldering process.

4. Control the temperature of the soldering iron tip: Ensure that the temperature of the soldering iron tip is within the appropriate range, avoiding being too high or too low.

5. Reasonably set welding time: Master the length of welding time and avoid being too long or too short.

6. Fixed welding components: Ensure that the components are fixed during the welding process to avoid virtual welding caused by loose components.

7. Regular inspection and maintenance of equipment: Regularly inspect and maintain welding equipment to ensure that it is in good working condition and avoid virtual welding caused by equipment problems.