Laser Welding Instructions: Tips, Precautions, and Skills
Updated Jun 19,2025
Updated Jun 19,2025
Safety Tips
Before laser welding, please be sure to watch the safety training video and wear personal protective equipment (laser safety goggles/helmet, mask/face shield, heat-resistant gloves).
For thin plates less than 1mm, the base material can be melted directly to form the weld seam without the need for additional welding wires.
If the weld seam is relatively small, it can also be welded using autogenous welding, which does not require additional welding wires.
Welding wire material
The basic principle is that the base sheet and the welding wire should be of the same material.
Materials
Grades
Recommended Wire
Shielding Gas
Stainless Steel
304 Stainless Steel
308L
99.99% Nitrogen or 99.99%Argon
316 Stainless Steel
316L
430 Stainless Steel
309L
Carbon Steel
Q235, 20#
ER70S-6
45#
ER50-6
Galvanized Sheet
DX51D, DX52D
ER70S-G / ER70S-6
Aluminum
1060
6061
6061, 6063
4043
5052
5356
Brass
H62
S221
Welding wire diameter
Please choose welding wire of proper diameters for metals of different thickness
The diameter of the welding wire should not be smaller than the gap of the weld, and the thickness of the workpiece is not recommended to be less than the diameter of the wire.
xTool MetalFab laser welder now supports wires of 0.8mm, 1.0mm, 1.2mm, 1.6mm.
For metals≥4mm, it's recommended to use 1.2mm wire. For metals of 2-3mm, it's recommended to use 1.2mm wire. For metals ≤1mm. it's recommended to use 0.8mm wire. This is only for recommendation, the final choice should be based on the welding results and demands.
Check Before Welding
Welding Focus Position
Confirm the welding nozzle scale is the same as the suggested value of system settings.
When installing the wire feeding tube, ensure that the welding wire fits snugly into the groove of the wire feeding nozzle to prevent the wire from being offset.