18

Laser Welding and Cutting

Lasers produce parallel, generally monochromatic, beams of non-

ionising radiation, which may be visible, ultraviolet or infrared. This
radiation can be focused to a point to produce intense heating for
laser welding and cutting. Lasers can yield high production rates
and can make deep penetration welds, with a minimal heat affected
zone, including joints between dissimilar metals, see Fig. 18.1.
There are several types of laser that may be encountered in
welding and cutting, identified by their active medium. Table 18.1
illustrates some typical uses.

Key Hazards
Key hazards are:
– laser radiation
– electrical
– fume and gas
– fire
– mechanical hazards from the workpiece handling system (or a
fibre optic beam delivery).

Laser radiation

The damage that laser radiation can do depends on its wavelength

and its power. The principle areas of concern are the effects on the
eye and the skin. Ultraviolet light affects primarily the cornea (surface
of the eye) causing arc eye, while visible light and near infrared
(roughly 400 nm to 1.4 mm) can enter the eye and will be incident
on the retina. Beyond 1.4 mm, the cornea is, once more, the affected
part.

162
 Laser Welding and Cutting 163

18.1 Laser welding.

Table 18.1. Typical uses for lasers

Laser type Output wavelength Typical applications

Helium–neon 633 nm (red) Alignment

Ruby 694 nm (red) (Now relatively uncommon) hole
drilling
Neodymium/YAG 1.06 mm (near Welding and cutting
infrared) Drilling
Can be used with a fibre-optic
delivery and robot manipulation
Carbon dioxide 10.6 mm (mid Welding
infrared) Cutting of metals, ceramics,
polymers and cloth
Heat treatment
Etching
Excimer lasers Ultraviolet Precision machining, drilling,
polymer ablation

Ultraviolet light will cause sunburn and premature ageing of the

skin. Laser light in the visible region may cause thermal damage
and changes in skin pigmentation; in the infrared the skin will be
burnt. The damage that the laser radiation can do is dependent on
the power of the laser. The wavelengths that can reach the retina are
particularly hazardous, since the eye focuses the radiation to a small
spot. This can result in almost instantaneous irreversible damage to
164 Health and Safety in Welding and Allied Processes

the sight. Note that the results of exposure to UV are delayed,

whereas the damage done by visible and infrared lasers is immedi-
ately apparent.
Because the hazards of lasers are not always immediately appar-
ent and they can be so severe, both the American Standards165 and
the UK Standards166,167 require the employer to appoint a laser safety
officer, to monitor the use of lasers, design the engineering controls
that are required and ensure that safe practices are adopted.

Laser classification

Lasers are classified on the basis of the maximum output power and
wavelength, Table 18.2. The manufacturer should label products
accordingly with appropriate warning labels. The labels are black on
yellow.
Class 1 is safe under all reasonably foreseeable circumstances,
classes 2 and 3 are more hazardous, and class 4 is the most haz-
ardous. In the latter class, the beam is hazardous even when dif-

Table 18.2. Classification of laser products

Class Description Type and content of labels

1 Inherently safe ‘Class 1 laser product’ (optional)

Also a higher class laser with
engineering controls such that
no radiation greater than class
1 can be accessed
2 Lasers emitting visible radiation,
where the human eye is
protected from damage by the
aversion response
3A* Lasers that are safe for viewing
with the unaided eye. The use
of optical aids (e.g. microscopes)
may be hazardous
3B Direct intrabeam viewing is
hazardous. Diffuse reflections
are normally safe
4 Lasers that can produce hazardous
diffuse reflections. They may
cause skin injuries and
constitute a fire hazard
Laser radiation. Do not stare into
beam. Class 2 laser product
Laser radiation. Do not stare into
beam or view directly with
optical instruments. Class 3A
product
Laser radiation. Avoid exposure
to beam. Class 3B laser product.
Aperture to be labelled
Laser radiation. Avoid eye or skin
exposure to direct or scattered
radiation. Class 4 laser product.
Aperture to be labelled

* Note that a class 3A laser under the US classification is not identical to the UK
classification.
 Laser Welding and Cutting 165

fusely reflected from a surface and also represents a significant fire

hazard.
Helium-neon lasers have too low a power output to be of any use
directly for welding and cutting but may be used in conjunction with
other types to align optical components and workpieces. Since the
output is in the visible spectrum, beam paths and point of focus are
easily seen with the naked eye. They will normally comply with
class 1 or 2. The majority of the materials processing lasers are in
class 4 and powers can be up to tens of kilowatts.

Precautions for class 4 lasers

The following facilities should be provided. Many will normally

be built-in by the manufacturer of the equipment and described
and illustrated in its accompanying documentation. However, the
incorporation of the laser into a working cell will normally be the
responsibility of the employer, who will also be responsible for
implementing the procedures.
An emission indicator device must clearly show when the laser is
energised. The laser should only be operated in a controlled area.
The laser radiation should be confined within a protective enclosure
where reasonably practicable. Warning signs of the approved type
should be placed at the points of access to the work area. Signs will
warn of the danger and the class of the laser and will include the
standard hazard symbol, Fig. 18.2.
There should be a remote interlock connected to room, door or
fixture circuits, to cut off power if doors are left open or are opened
while the laser is energised. In the case of a pulsed laser, these inter-
locks should also cause the stored energy to be discharged. The laser
should be operated by remote control if possible so that personnel
are clear of the work area. Operation should only be possible by the

18.2 Hazard warning symbol for laser radiation (black on

yellow background).
166 Health and Safety in Welding and Allied Processes

use of a key and this key should be removed when the equipment
is not in use to prevent unauthorised operation.
As far as possible, beams should be enclosed, but if unprotected,
beams should be well above or below eye level. Specular (mirror-
like) reflections should be avoided by mounting mirrors and lenses
rigidly and by avoiding polished surfaces, such as personal jewellery
and tools, in the vicinity of the beam path. Note that surfaces which
appear quite rough in visible light may give specular reflections at
a wavelength of 10.6 mm. For class 4 lasers, even diffuse reflections
have the potential to be harmful and should be avoided. Alignment
of the beam should be done using low power lasers.
A beam attenuator and/or beam stop, capable of safely absorbing
the available energy should be placed to cut down the energy as
much as practicable and to terminate any residual beams. Panels
which are removable for servicing, etc, must have interlocks to
prevent exposure if they are removed. If any interlock is provided
with an override mechanism, there must be a warning notice and a
visible or audible warning.
Personnel who may be exposed to radiation should wear clothing
with appropriate resistance to fire. All operation and maintenance
personnel should receive appropriate training including:
– operating procedures
– hazard control procedures
– personnel protection
– accident reporting
– bio-effects of the laser.

Protective filters

Where engineering and administrative controls cannot substantially

eliminate the risk of exposure in excess of the maximum permis-
sible exposure, eye protection should be provided, clearly marked
to ensure proper choice.165,168,169 However, it should be noted that
eye protection is the last resort – engineering controls to prevent
exposure should always take precedence. Eye protection is unlikely
to be able to protect the wearer against exposure to the direct
beam.
The windows to the engineering enclosure of the beam may be
furnished with filter material, to allow a view of the workpiece while
ensuring that laser radiation cannot be transmitted. As with arc
 Laser Welding and Cutting 167

welding, good room illumination and matt, light coloured walls are
desirable to give operators a good view through protective filters.
As only special materials will transmit the 10.6 mm radiation of the
carbon dioxide laser, there is little difficulty in making some or all
of the protective enclosure of plastic sheet transparent to visible
light. Note however, that if the full beam impinges on the screen
material it may melt through. Operators should be further protected
by wearing clear plastic visors.

Electrical hazards

All equipment should be installed in accordance with the National

Codes.18,19,156 Pulsed ruby and neodymium lasers draw their electri-
cal input energy from a capacitor bank or pulse-forming network
charged to several kilovolts. Interlocks are required to prevent live
parts being touched until the mains supply has been cut off and the
stored energy safely dissipated.
Carbon dioxide lasers have a substantial high voltage supply, often
enclosed within the case needed to protect the optical components.
If a flexible cable carries the supply from a separate power unit, it
must be suitably protected and inspected regularly for damage.
Water leaks must always be repaired promptly, especially when
the water is routed with the electrical cables.
Only those suitably trained and competent should attempt to work
on the power supply of a laser. Fatal accidents have occurred.
Power supplies should be provided with an automatic discharge
and grounding circuit that is actuated when the laser is turned off.
There should be discharge and grounding interlocks on all access
panels. The maintenance engineer should be provided with a
grounding rod for manual verification of complete discharge. He or
she should wear safety glasses when undertaking this operation
since explosion-like discharges can take place. There should be
grounding straps to prevent charge from building up.

Fume and gas

Substantial amounts of fume may be emitted in work with high

power carbon dioxide lasers, particularly when cutting with the use
of oxygen. Fume hazards and preventive action are discussed in
Chapters 5 and 6; the enclosure that protects the operators from the
laser beam should incorporate an appropriate extractor as necessary.
168 Health and Safety in Welding and Allied Processes

Gases in cylinders present the hazards described in Chapter 4, and

require safe storage and handling.

Fire

High power class 4 beams can set articles on fire. Ensure that the
beam is always stopped at the end of its useful path by a beam stop
that absorbs the radiation safely without catching fire. Ensure a good
standard of housekeeping so that there is no combustible rubbish
which the beam could set on fire.

Mechanical hazards

Lasers are capable of very high welding speeds and therefore it

follows that either the beam must be moved rapidly, or the work-
piece. For gas lasers, it is common to use an X-Y traverse to manip-
ulate the workpiece. Fibre optic delivery of the Nd-YAG laser allows
the laser itself to be manipulated by a programmable robot.
When working at full speed, the manipulators should be within
the laser enclosure, and therefore separated from the work force.
However, it is usually necessary to program the motion in advance.
This will normally be done at a reduced speed, with such devices
as ‘hold to run’ controls. Chapter 9 and the references relating to
robots give further information.120–122