Material Guide

Laser Welding Aluminum

Aluminum is challenging to weld, but laser makes it easier. Learn settings, tips, and why fiber laser excels on aluminum.

Why Laser for Aluminum?

Low Heat Input

Minimal distortion on thin aluminum

Fast Speed

5-10x faster than TIG welding

Easy to Learn

No arc starting skills needed

Wobble Head

Breaks oxide layer, wider weld pool

Minimal Cleanup

No spatter, no post-weld grinding

Wire Feed

Automatically adds filler for gap filling

Aluminum Welding Challenges & Solutions

High Reflectivity

→ Use higher power initially, fiber laser reflects less than CO2

Oxide Layer

→ Wobble head breaks oxide, or pre-clean surface

High Conductivity

→ Fast travel speed, higher power than steel

Hot Cracking

→ Use filler wire (4043/5356), control heat input

Porosity

→ Clean surface, pure argon gas, good shielding

Recommended Settings by Alloy

Alloy	Power	Speed	Filler Wire
1100/3003 (Soft)	1200-1500W	20-30mm/s	4043
5052/5083 (Marine)	1500-2000W	15-25mm/s	5356
6061/6063 (Structural)	1500-2000W	18-28mm/s	4043
7075 (Aerospace)	1800-2500W	12-20mm/s	4043/5356

* Settings for 2mm material thickness. Adjust power up for thicker material.

Pro Tips for Laser Welding Aluminum

⚡ Power Settings

• Start 20-30% higher than steel of same thickness
• Use pulse mode for thin material
• Increase wobble width for better coverage

🧹 Surface Prep

• Remove oil/grease with acetone
• Stainless brush to remove oxide (optional)
• Weld soon after cleaning

💨 Gas Shielding

• Use pure argon (not CO2 mix)
• Higher flow rate than steel (20-25 CFH)
• Keep nozzle close for good coverage

🔩 Wire Selection

• 4043: Most common, good color match
• 5356: Stronger, marine applications
• Match wire to base alloy when possible

Ready for Easy Aluminum Welding?

Get a fiber laser welder that makes aluminum welding simple.

Get Free Quote