Prepare the workspace and the machine

For the preparation of the workspace, machine, and other necessary devices, refer to the following guides:

• Preparation Work Before You Use xTool MetalFab Laser Welder & CNC Cutter
• Install xTool MetalFab Laser Welder 1200W
• How to Install and Set the Wire Feeder?

Prepare the workpieces and welding wire

xTool MetalFab Laser Welder 1200W supports welding the following materials: stainless steel, carbon steel, galvanized steel, aluminum, and brass. 

Refer to the following table to select a proper wire based on the material type.

To ensure proper metal melting and fusion during welding, ensure that the surface of the workpiece is clean. If the surface of the workpiece is dirty (e.g., covered with grease, rust, coatings, or dust), clean it with alcohol or acetone or polish it. 

Start wire-filled welding

Note: Before operating the device, please follow the safety instructions to put on PPE and take proper safety precautions. Necessary PPE includes: laser safety goggles, welding helmets, dust mask, laser and heat-resistant gloves, clothing, and aprons.

1. Turn on the shielding gas supply and adjust the gas flow rate to 15 L/min – 30 L/min.

Supported gas types: nitrogen or argon (Purity > 99.99%)

(1) Open the gas cylinder valve	(2) Press and hold the grip sensing button and trigger to allow gas flow. Meanwhile, adjust the gas flow rate to 15 L/min – 30 L/min.

Cautions:
■ The way of opening the valve may differ for different types of gas cylinders. The picture is for illustration only.
■ To prevent accidentally triggering laser emission, ensure that Enable lasering is off on the touchscreen before operations.

2. Place the workpiece stably on a metal base or other support.

Caution: Ensure that the welding part is suspended without touching the support. Otherwise, the material melted during welding may stick to the support.

3. Clamp the workpiece sensing cable to the workpiece or to a conductive object connected with the workpiece, such as a metal base or a metal desktop.

Danger: It is strictly prohibited to attach the clamp to the graduated tube of the welding head.

About the safety interlock loop
A safety interlock loop exists between the welding head, the workpiece, and the main unit. Only when the welding head is in contact with the workpiece can the safety interlock loop be closed and allow the welding head to emit laser beams.

4. On the welding head, use the feed and retract buttons to adjust the wire until its tip coincides with the red spot.

Note: If the red spot is not visible or blurred, or falls at the left or right side of the extended wire, please calibrate the position of the red spot before welding. For the calibration guide, see Calibrate the Red Light Position.

5. Turn on the wire feeding enable switch to enable the auto feeding function.

About the wire feeding enable switch
The welding head feeds wire automatically during welding only when the wire feeding enable switch is turned on.

6. On the touchscreen, choose Standard mode > Weld. Select the material type, material thickness, and wire diameter according to the actual situation.

You can also set the welding parameters under other modes:
· Advanced mode: offers more welding selections and control over the basic welding parameters
To enter the advanced setting mode, tap Advanced mode on the left or Switch to advanced mode with current settings in the bottom left.

· Professional mode: offers full control over all welding parameters
To enter the professional setting mode, enter the Advanced mode > turn on Professional in the bottom left.

Note: For parameter explanations, see How to Choose Welding Parameters?

7. On the touchscreen, tap Enable wire feeding to allow wire feeding and Enable lasering to allow laser emission.

8. Align the welding parts.

9. Aiming the welding nozzle at the starting point, press and hold the grip sensing button and trigger to start welding.

Tips:
■ Ensure that the welding head tip contacts with the welding target, so that the safety interlock loop can be closed and the welding head can emit laser.
■ During welding, simply hold the welding head steadily and guide the direction. Do not push, pull, or press the welding head.
     · As the welding head feeds the wire forward, a reaction force is generated from the welding point that automatically pushes the welding head backward.
     · To avoid wire sticking or clogging, do not press the welding head downward.
     · Ensure that the welding head moves in the same direction as the welding seam.

Cautions:
■ During welding, ensure that no one stands in the laser reflection zone, watches from the reflection zone, or places a hand in the reflection zone.
■ After the welding is completed, the workpiece and parts of the welding head (such as the nozzle and the graduated tube) will remain hot for some time. Do not touch the hot areas without protection.
■ After the welding is completed, turn off Enable lasering on the touchscreen to prevent accidental laser emission.

More information

If the welding does not go smoothly, or if the welding result is not as expected, refer to the following documents for solutions:

• Troubleshoot Weld Bead Offtrack
• Troubleshoot Discontinuous Weld Beads
• Troubleshoot Concave and Convex Weld Beads
• Troubleshoot Welding Wire Sticking to the Workpiece
• Troubleshoot Burn-Through for Laser Welding
• Troubleshoot Incomplete Penetration for Laser Welding

• Troubleshoot Laser Emission Failure for xTool MetalFab Laser Welder
• Troubleshoot Wire Feeding Failure for xTool MetalFab Laser Welder 1200W
• Troubleshoot Improper Wire Melting and Filling for xTool MetalFab Laser Welder
• Troubleshoot Erratic Wire Feeding for xTool MetalFab Laser Welder