Laser welding vs TIG welding has been a hot debate in the metal fabrication sector. Some people consider laser welding a superior and more advanced option. Indeed, this method has many advantages, making it a choice for many. However, TIG welding offers a value proposition, presenting itself as a decent option.
In such cases, the selection of laser or TIG welding becomes confusing. Therefore, their selection requires detailed knowledge of both methods. In this article, I’ll explain everything about laser and TIG welding. After reading this piece, you’ll be able to choose one of these two welding methods easily.
Basic Rundown of Laser & TIG Welding
Before comparing laser and TIG welding, let’s examine the basics of these two methods.
Laser welding utilizes high-energy, highly focused laser beams. This laser beam is potent and has intense heat. This heat easily melts the metal pieces. After that, the molten pieces undergo cooling. When they cool down, they fuse with a strong joint or weld.
Welding methods vary in technique and application. However, laser welding is the fastest among all these methods and creates the joint very quickly. Additionally, the joints made with this method are a masterpiece of precision. However, this process is expensive, which is a kind of drawback. Let’s discuss the counterpart, TIG welding.
TIG welding is a slower but relatively inexpensive process. It uses a non-consumable tungsten electrode which produces an electric arc. This electric arc melts the metal piece. A separate filler material is fed during the welding process. This filler is also consumed, creating a strong joint between the edges of the metal pieces.
TIG welding is widely used because it produces high-quality work at an affordable price. In this type, the usage of shielding gas is mandatory. Its purpose is to block air from making contact with the molten material and prevent surface contamination. This method is considered the best suited for creating strong and neat welds on thin materials.
What are the Differences Between Laser Welding and TIG Welding?
I mentioned earlier that these two types of metal sheet welding differ from each other in many aspects. From precision to weld quality and speed, their distinctions make them suitable for different needs. In the section below, I’ll explain all of the differences between laser and TIG welding. This section will help you select the appropriate welding technique for your specific needs.
1- Heat generation & HAZ
Both of these methods employ different methods of heat generation. In laser welding, a highly focused, intense laser beam is used. This beam melts the material, helping to create a strong joint. On the other hand, the TIG welding technique produces heat through an electric current. As I said earlier, this method uses a non-consumable tungsten electrode.
First, the TIG welding machine is switched on. Now, when you bring an electrode close to a metal piece, an electric arc is produced between the electrode and the metal piece. This arc has high energy and efficiently melts the metal piece. The HAZ refers to the Heat Affected Zone. The laser welding method produces little to no HAZ.
The reason is that the laser beams used in this method are very focused. They only melt the weld location. So, heat spread is minimal, resulting in no HAZ. The TIG welding method produces a HAZ, which can be a drawback, especially when welding thin materials. The heat is not concentrated at a single point, but rather it can spread across the material.
2- Material & Thickness Compatibility
The laser welding technique is very versatile and powerful. It can create strong and high-quality welds on all types of materials. If any material has a higher melting point, you can increase the power of lasers, melt such pieces, and create a weld. Additionally, this welding method can also weld both thicker and thinner materials.
TIG welding is also decent and can weld different types of materials. These include aluminum, steel, and others. However, they are more suitable for welding thinner material or pieces. When it comes to welding thicker materials, the speed of this welding process gets very slow. Therefore, I don’t consider it a practical option when it comes to welding thick materials.
3- Efficiency & Weld Quality
The laser welding technique utilizes a high-energy laser beam to quickly melt the metal pieces. When those molten pieces cool, they fuse and form joints. This process is completed in seconds, making it extremely fast and highly efficient for bulk production.
On the other hand, TIG welding is a slower and less efficient process. You’ll have to feed the filler manual, which consumes even more time. When it comes to weld quality, laser welding still gets the edge as it creates neat welds with excellent precision. However, TIG welding also produces a decent weld or joint on thinner material, which makes it stand out.
The laser welding technique may not create a strong and neat weld on thin materials. However, the weld quality in TIG welding depends on operator skills. The operator will hold the torch and manually feed the filler at a time, making this process a bit challenging. The highly skilled operator can create high-quality welds even on thin materials.
4- Automation & Skilled Requirements
The laser welding is a more advanced welding type. The laser-based welding machines also come with top-notch automation. Those automations increase the speed, performance, and precision of this welding process. However, the overall working of laser welding is relatively straightforward. The operation is basic knowledge of how to create strong and high-quality welds using laser welding.
On the other hand, TIG welding is less automation-friendly. The machines used in this method are also simple and less automated. Their work is somewhat complex, which is a significant drawback. The operator must possess the necessary skills and experience to effectively utilize this method. During welding, the operator holds the torch and feeds filler material while ensuring the weld is made in the right spot. This multiple tasking makes this process more challenging, especially for newbies.
5- Operation Safety & Filler Material
Both laser and TIG welding methods are generally safer. Modern laser welding machines feature enclosed systems where laser welding occurs. However, the laser light spark is usually potent and can cause damage to the eyes.
Therefore, you must wear goggles and gloves when doing this welding. Similarly, TIG welding is also safer, but you should use goggles and other safety tools. The spark from the electric arc can be harmful to the skin and eyes. If you use basic precautionary measures, you can avoid the issues. The laser welding generally doesn’t use filler materials.
The laser melts the pieces, which then fuse, creating a weld. However, the TIG welding always needs filler. If there is a gap between pieces, the filler material is melted onto the fuses that fill that gap. Without filler, this TIG welding can be very challenging and create a weak weld. Laser welding only needs filler when the gap between two pieces is huge.
Quick Highlight: Both of these welding types produce fumes during their operations. These fumes are generally harmful to health. Therefore, I highly recommend wearing a face mask when using any of these techniques to create a weld. If you inhale these fumes, they can pose serious health issues. This safety measure is essential for both types of welding.
6- Welding Speed And Productivity
As I said earlier, laser welding is a speedy and efficient process. The lasers used in this method are very intense and powerful. They instantly heat and melt the metal pieces. When those pieces cool down, they fuse to create a weld. Moreover, this method is precise, which is a significant advantage.
On the other hand, TIG welding is a very slow and time-consuming process. Additionally, it also needs separate filler material to create the weld. The operator will have to hold the torch in one hand and the filler in the other. Additionally, operators will have to work slowly to avoid any mistakes. This affects the productivity of this TIG welding.
7- Shielding Gas And Heat Distortion
I previously discussed the use and importance of shielding gas in a Laser vs. MIG welding guide article. This gas is blown onto the weld to prevent the molten material from reacting with oxygen in the air. Suppose this reaction occurs between molten material and air.
In such cases, there will be more surface contamination on the weld due to the oxidation process. The laser welding technique emits laser beams, melts pieces, and makes joints quickly. Due to this fast operation, this process does not need shielding gas. It is optional, and you can use it as a precautionary measure.
However, the usage of shielding gas is mandatory in the TIG. The reason is that this process is slower. Therefore, the chances are high that the molten material will react with air, as it takes more time to solidify. Consequently, you will have to use argon or nitrogen as shielding gas in this process. When it comes to heat distortion, I consider the laser technique a superior option.
The reason is that it uses a high-focus laser beam that melts only weld points. This heat does not spread and causes heat distortion issues. On the other hand, heat distortion can occur during TIG welding. The reason is that the heat source (arc) can heat a larger portion of the material, rather than focusing solely on the weld location.
8- Cost & Applications
Laser welding is more costly compared to MIG or TIG welding. The cost of laser welding machines, tools, and their maintenance is very high. These factors significantly increase the cost of the process. This higher cost of this process can be a big downside for many people. The TIG welding is relatively inexpensive.
The reason is that TIG welding machines are affordable and require very little maintenance. The higher pricing of laser welding is worth it due to its top-notch precision and fast speed. When it comes to applications, both of these techniques are used in different sectors. Laser welding is used in large-scale projects. TIG welding is commonly used in smaller repair work.
Here is a table comparing their applications:
| Laser Welding Applications | TIG Welding Applications |
| EV battery tab welding. | Stainless steel sink welding |
| Medical implants and pacemakers. | Bicycle and motorcycle frame welding |
| Smartphone sensors and micro parts. | Aircraft aluminum repair |
| Automotive gear and transmission parts. | Custom exhaust pipe fabrication |
| Precision micro-metal components | Artistic and decorative metalwork |
| Circuit board spot welding. | Welding aluminum fuel tanks |
| Aerospace titanium component welding. | Copper and stainless steel pipe joints |
| Razor blade seam welding. | General repair and hobby welding |
Laser or TIG Welding: Which Should I Choose?
Choosing between these welding methods depends on your budget and preferences.
I consider laser welding a better option as compared to TIG welding. It creates strong welds with precision in a swift manner. Additionally, it does not produce large HAZ, which is a significant advantage. You won’t have to use a separate filler to create a reliable weld or joint.
However, this laser welding process is costly, which can be a big hurdle. If the budget is your concern, you should opt for TIG welding. This process is cost-effective and can create strong welds on thinner material. The cost of a TIG welding machine is very low, ensuring its cost- effectiveness.
Additionally, the welders have more control over weld quality due to manual feeding of filler. With the proper skill and expertise, you can create precise welds. However, the speed of TIG welding is something that is a big NO-NO for me. It takes more time, even when making a simple weld, which affects productivity.
Frequently Asked Questions
Is laser welding stronger than TIG welding?
Yes, laser welding creates a strong weld or joint with precision and accuracy. During this welding, no surface contamination happens. The created weld is strong and lasts for many years without undergoing deterioration.
What is the disadvantage of laser welding?
First, laser welding is not ideal for creating welds on thinner pieces. Additionally, it produces fumes that can be harmful to the operator’s health. Additionally, the cost of laser welding machines is very high, making this process costly.
Why are laser welders so expensive?
The initial cost of a laser welding machine is very high. Additionally, these machines have more features related to automation features. Those additional features require regular maintenance, making this process expensive.
Conclusion
Both laser and TIG welding offer excellent value propositions. TIG welding is generally preferred for smaller-scale productions. Its slower speed and less efficiency limit it to small repair works. The Laser welding is more advanced and known for its precision and speed.
Manufacturers use it for large-scale production due to its higher cost. In this article, I discussed all the key differences between these two methods. I highly recommend doing a complete analysis of your needs before making a selection decision. Both of these welding techniques fit different needs and applications.