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).
 

Gas Suggestions

Gas Suggestions for xTool MetalFab

Processing Type

Material Type

Recommended Gas

Recommended Pressure

Recommeded Nozzle

CNC Cutting

Stainless Steel

99.99% Nitrogen or

Over 87 PSI (0.6 MPa)

Ordinary cutting nozzle

Aluminum

99.99% Argon or

(included in CNC cutter package)

Brass

Compressed Air

 

Carbon Steel

 

 

Galvanized Sheet

 

 

(0.2mm-1mm)

 

 

Stainless Steel (2mm-5mm)

99.99% Nitrogen or

Over 174 PSI (1.2 MPa)

Ordinary cutting nozzle

Aluminum (2mm-4mm)

99.99% Argon or

(included in CNC cutter package)

Brass (2mm-3mm)

Compressed Air

Over 87 PSI (0.6 MPa)

SaveGas Nozzle

 

 

((included in CNC cutter package)

Titanium Alloy TC4 (1mm)

99.99% Argon

Over 174 PSI (1.2 MPa)

Ordinary cutting nozzle

(included in CNC cutter package)

Titanium Alloy TC4 (2mm-5mm)

SaveGas Nozzle

((included in CNC cutter package)

Carbon Steel (2mm-10mm)

99.99% Oxygen

8.7 PSI-10.2 PSI

Double-layer Nozzle & focus extension tube

Galvanized Sheet (2mm-10mm)

(0.06 MPa-0.07 MPa)

(add-on)

CNC Cleaning

Stainless Steel

99.99% Nitrogen or

87 PSI-116 PSI

CNC Cleaning Nozzle

Aluminum

99.99% Argon

(0.6 MPa-0.8 MPa)

(included in CNC cutter package)

Brass

 

 

 

Carbon Steel

 

 

 

Galvanized Sheet

 

 

 

Welding

Stainless Steel

99.99% Nitrogen or

15-30L/min flow rate or 14.5 PSI-29 PSI (0.1 MPa-0.2 MPa) pressure

Welding Nozzles

Aluminum

99.99% Argon

(included in laser welder package)

Brass

 

 

Handheld Cleaning

Carbon Steel

 

Cleaning Nozzle

Galvanized Sheet

 

(included in laser welder package)

Handheld Cutting

 

99.99% Nitrogen or

Over 116 PSI (0.8 MPa) pressure

Handheld Cutting Tip

 

99.99% Argon or

(included in laser welder package)

 

Compressed Air

 

Welding Wire Options

Welding wire or not?

Not all welding processes require welding wires.
  • 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.
 
 

Welding wire position

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.
 

Red light position

Before welding, check that the welding wire is aligned with the center of the red light.
 
 

Protective lens

Check if the lens is dirty or damaged.

Welding Tips

  • Choose the proper welding parameters according to your demands. (How to Choose Welding Parameters?
  • The welding nozzle of the welding gun should be inclined at a 45° angle to the weld seam.
Correct angle:
 
 
Incorrect angle:
 
  • The welding wire must not deviate from the weld seam.
  • During wire feeding, do not pull the wire with your hand; the wire feeder will drive the welding gun automatically.
Hands pulling the wire, too high speedAuto wire feeding, proper speed
 
  • After welding, manually lift the gun to avoid wire sticking.
  • It is recommended to perform tack welding first, followed by continuous welding.
  • When welding, leave space for deformation.
 
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