An OEM in the energy sector has a fully engineered, validated, and released component used in a critical system. But producing it in‑house has become a bottleneck. Internal resources are stretched, suppliers are fragmented, and coordinating machining, welding, assembly, and inspection across multiple vendors consumes valuable time. This is where build-to-print manufacturing services provide a more efficient, scalable solution.
That’s where Joining Technologies steps in.
The OEM provides complete drawings, specifications, and quality requirements. Our team reviews the package, sources materials, performs precision machining, welding, assembly, testing, and final inspection — all under one roof.
Consolidating manufacturing reduces risks such as:
Miscommunication between vendors
Quality inconsistencies between suppliers
Schedule delays from fragmented production
Traceability gaps during inspection or testing
Finished parts are delivered on schedule, supported by a tailored stocking program to keep production running smoothly.
The Result
Your engineering team stays focused on new product development
Supply chain complexity is dramatically reduced
Lead times become predictable
Quality is consistent from run to run
For customers with a proven design and the need for repeatable, scalable production, Joining Technologies’ Build‑to‑Print manufacturing services transform manufacturing challenges into long‑term solutions.
Supporting Long-Term Production
Our customer relationships have grown from transactional service engagements to fully trusted partnerships. While we once provided individual services such as welding or additive repair, today our build‑to‑print customers rely on us to manage the entire supply chain for their complex precision assemblies.
As a true one‑stop shop, we simplify their workflow. Our experts understand every product requirement in detail, eliminating the need to coordinate multiple vendors. Unlike others, we keep all critical capabilities under one roof—allowing us to ramp up production quickly and seamlessly integrate key services such as machining, assembly, welding, marking, and final testing.
When production volumes grow, as your trusted manufacturing partner, we can provide:
scalable production solutions
superior supply chain management
inventory and stocking strategies
The result is a manufacturing partnership that supports both current production and future growth.
What Is Build‑to‑Print?
Build‑to‑print is a manufacturing approach in which the customer supplies complete drawings and specifications — and a trusted partner handles every step of execution. Unlike design‑for‑manufacture services, build‑to‑print begins after engineering is complete, freeing you to focus on innovation while we produce with precision.
At Joining Technologies, we enhance this model by integrating machining, assembly, welding, inspection, and testing into a single facility, backed by decades of specialized expertise.
From Design to Delivery: What You Get
🔹 Precision Review & Planning
We begin by reviewing your documentation to confirm manufacturability, material requirements, and process optimization.
🔹 Material Procurement
We source high‑grade materials that meet your exact specifications and industry standards.
🔹 Advanced Processing & Fabrication
From CNC machining to precision welding and specialized fabrication techniques, every component is produced with meticulous attention to detail.
🔹 Assembly & Functional Testing
Our technicians assemble and test your parts to ensure consistent performance and full compliance with requirements.
🔹 Stocking & Inventory Management
Keep production moving with custom stocking programs that ensure parts are available when you need them.
Industries Served
Our build‑to‑print manufacturing services support industries where precision, reliability, and quality are non‑negotiable, including:
Aerospace
Medical devices
Energy and power generation
Defense and national security
Industrial machinery
Whether your components must withstand high temperatures, tight tolerances, mission‑critical environments, or regulatory scrutiny — we’re equipped to meet the challenge.
Ready to Build Better?
Contact our team to request a quote or speak with an expert about how Joining Technologies can support your next project.
Build-to-Print Manufacturing FAQ
How is build-to-print vs build-to-spec or contract manufacturing?
Model
Scope
Build-to-Print
The manufacturer produces exactly according to the drawings
Build-to-Spec
Create from pre-existing designs and specifications
Contract Manufacturing
An outsourced production relationship that may include either approach
What information is required to start a build-to-print project?
Manufacturers typically need a complete documentation package. This often includes:
Engineering drawings and CAD files
Material specifications
Tolerance requirements
Assembly instructions (if applicable)
Inspection and testing criteria
Quality or regulatory requirements
Providing clear documentation allows us to review the design, plan production, and ensure the final product meets all requirements.
Can build-to-print manufacturing services include assembly and testing?
Yes. Many build-to-print programs extend beyond producing individual components. Depending on the project, services may include:
Subassembly or full product assembly
Functional testing
Leak testing or pressure testing
Documentation and inspection reporting
Integrating these steps into the production process helps ensure the final product performs as expected upon delivery.
Can Joining Technologies help if I need support finishing the design?
While build-to-print starts with a fully released design, we can assist customers who need support with manufacturing best practices. Our team can review your drawings and suggest manufacturability improvements.
When you’re already investing in precision welding, machining, build-to-print manufacturing, or laser cladding services, there’s an opportunity to get even more value from your parts by adding laser marking as part of the same process. Laser marking is a simple, efficient way to enhance traceability, quality, and usability—without adding complexity to your supply chain.
For many projects, it’s an easy upgrade that pays dividends throughout the entire life of the part.
What Is Laser Marking?
Laser marking is a non-contact process that uses a focused laser beam to permanently mark information directly onto a component’s surface. Depending on the material and application, this can include serial numbers, part numbers, lot codes, barcodes, logos, or compliance markings.
Unlike labels, ink, or mechanical engraving, laser marks are permanent, precise, and resistant to wear, heat, and chemicals. The result is clear, consistent identification that lasts as long as the part itself.
Improved Traceability from Day One
Traceability is increasingly critical across industries, from aerospace and medical devices to energy and industrial manufacturing. Laser marking enables permanent, readable identification that supports quality control, regulatory compliance, and lifecycle tracking.
By incorporating laser marking during manufacturing, parts can be:
Serialized for full traceability
Linked to material certifications and inspection records
Easily identified during assembly, installation, or service
Because the marking is done in-house as part of the production flow, it eliminates the need for secondary vendors or post-processing steps that can introduce delays or errors.
Protecting Quality Without Compromising Performance
One of the biggest advantages of laser marking is that it does not compromise part integrity. As a non-contact process, it introduces no mechanical stress, distortion, or tool wear. When properly applied, laser marking preserves tight tolerances and does not affect welds, coatings, or critical surfaces.
This makes it ideal for high-precision components, thin-walled parts, and assemblies where traditional marking methods may pose a risk.
Streamlining Your Supply Chain Through Laser Marking Add-On Services
Adding laser marking at the same facility where your parts are welded, machined, or clad simplifies logistics. Instead of coordinating multiple suppliers and shipments, everything is handled in a single, controlled environment.
That consolidation offers real benefits:
Reduced lead times
Lower handling and transportation risk
Consistent quality standards across processes
Fewer handoffs and less administrative overhead
For production programs or repeat orders, this streamlined approach can significantly improve efficiency and predictability.
Enhancing Usability and Long-Term Value
Clear, permanent markings make parts easier to identify long after they leave the factory floor. Maintenance teams, inspectors, and end users benefit from markings that remain legible through years of service, exposure, and handling.
Whether it’s a technician scanning a barcode, an inspector verifying a serial number, or an operator confirming part orientation, laser marking improves usability well beyond initial delivery.
A Small Add-On with a Big Return
When you’re already manufacturing a part, laser marking is often a minor addition in terms of cost and time—but one that delivers long-term value. From improved traceability and quality assurance to simpler logistics and better end-user experience, it’s a smart way to get more from every component you produce.
If you’re looking to maximize the return on your manufacturing investment, laser marking isn’t just an extra step, it’s a strategic one.
If you have questions about laser marking add-on services or would like to have this service added to your project, please contact us.
There are many different types of welding, but the right process depends on the material, part design, production requirements, weld quality expectations, and how much heat or atmospheric exposure the component can tolerate.
For precision manufacturing applications, some of the most important welding methods include laser welding, electron beam welding, gas tungsten arc welding, and resistance welding. Each process offers different advantages depending on the required weld depth, cleanliness, repeatability, distortion control, and material sensitivity.
At Joining Technologies, we specialize in advanced welding services for demanding applications in aerospace, defense, medical devices, energy, automotive, and advanced manufacturing. This guide compares several key welding methods and explains when each process is typically used.
What Are the Main Types of Welding Offered by Joining Technologies?
Joining Technologies provides several advanced welding and joining processes, including:
Laser Welding – A high-precision welding process that uses focused light energy to create narrow, repeatable welds with low heat input.
Electron Beam Welding / EBW – A vacuum-based welding process that uses a focused beam of electrons to produce deep, clean welds with minimal distortion.
Gas Tungsten Arc Welding / GTAW / TIG Welding – A versatile arc welding process known for clean, high-quality welds and excellent operator control.
Resistance Welding – A process that joins materials using pressure and electrical resistance, commonly used for sheet metal, tabs, seams, and high-volume joining applications.
Some applications may also require additional atmosphere control, such as laser welding performed inside a glovebox or controlled inert atmosphere. This is not a separate welding process, but a specialized setup used when sensitive materials need protection from oxygen, moisture, or contamination.
While other welding processes exist, these methods are especially valuable for precision components, high-performance assemblies, and applications where weld quality, repeatability, and process control are critical.
Welding Types Compared
Welding Type
Best For
Key Advantage
Main Limitation
Laser Welding
Precision parts, thin materials, medical devices, electronics, aerospace components
Stainless steel, aluminum, aerospace parts, medical components, precision assemblies
Clean, high-quality welds with strong process control
Slower and more operator-dependent
Resistance Welding
Sheet metal, tabs, seams, battery components, production parts
Fast and repeatable for specific joint types
Limited to certain geometries and material stacks
Laser Welding: High Precision, Speed, and Low Distortion
Laser welding uses a focused beam of light to join materials with a small, concentrated heat source. Because the energy is highly localized, laser welding can create narrow welds with minimal distortion and a small heat-affected zone.
This makes laser welding a strong choice for precision parts, thin materials, small assemblies, and components where dimensional stability is important. It can also be automated for repeatable production welding.
Advantages of Laser Welding
Fast processing speeds
Narrow, precise welds
Low heat input compared to many conventional welding methods
Minimal distortion
Excellent repeatability
Strong option for thin materials and precision assemblies
Can reduce the need for post-weld finishing
Limitations of Laser Welding
Requires accurate joint fit-up
Not ideal for poor part fit or large gaps
Process parameters must be carefully controlled
Higher equipment requirements than more basic welding methods
Common Laser Welding Applications
Laser welding is commonly used for medical devices, electronics, sensors, aerospace components, automotive assemblies, battery components, hermetic sealing, and precision manufactured parts.
It is often selected when speed, accuracy, repeatability, and minimal heat input are priorities.
Laser Welding in a Glovebox or Inert Atmosphere
Some laser welding applications require additional protection from oxygen, moisture, or atmospheric contamination. In these cases, the laser welding process may be performed inside a glovebox or controlled inert atmosphere.
This approach is especially useful for reactive metals, contamination-sensitive components, and critical assemblies where standard shielding gas may not provide enough protection. By combining laser welding with a controlled atmosphere, manufacturers can reduce oxidation, discoloration, contamination, and weld quality issues.
Glovebox welding is best understood as a controlled-atmosphere welding setup rather than a separate welding process. For example, laser welding may be performed inside a glovebox when the part or material requires additional environmental protection during welding.
Electron Beam Welding: Deep Penetration and Clean Welds
Electron beam welding, also known as EBW, uses a focused beam of high-velocity electrons to generate heat and fuse materials. The process is performed in a vacuum, which helps protect the weld from atmospheric contamination.
EBW is known for producing deep, narrow welds with high strength and low distortion. It is often used for critical components where weld integrity, penetration, and cleanliness are essential.
Advantages of Electron Beam Welding
Extremely deep weld penetration
Narrow welds with low distortion
Clean welds due to vacuum processing
Strong option for thick or dense materials
Excellent for critical, high-performance components
Can often reduce the need for multiple weld passes
Useful for applications requiring precise energy control
Limitations of Electron Beam Welding
Requires a vacuum chamber
Part size is limited by chamber capacity
More specialized than many common welding methods
Best suited for applications where the performance benefits justify the process requirements
Common Electron Beam Welding Applications
Electron beam welding is commonly used in aerospace, defense, power generation, medical devices, sensors, hermetic assemblies, and advanced manufacturing.
It is often selected for parts that require deep penetration, high strength, low contamination, and tight process control.
Gas Tungsten Arc Welding: Precision and Versatility
Gas tungsten arc welding, also known as GTAW or TIG welding, uses a non-consumable tungsten electrode and an inert shielding gas to protect the weld area. GTAW is known for producing clean, strong, high-quality welds with excellent control.
GTAW is often used when weld quality and visual appearance matter more than maximum speed. It is a strong option for stainless steel, aluminum, nickel alloys, titanium, and other materials used in demanding applications.
Advantages of GTAW
Produces clean, high-quality welds
Works with a wide range of metals and alloys
Provides strong control over heat input
Creates minimal spatter
Can be used with or without filler material
Well suited for precision and critical welds
Limitations of GTAW
Slower than laser welding or some automated processes
Requires a high level of operator skill
Less efficient for high-volume production unless automated
May not be ideal for very deep welds in thick sections
Common GTAW Applications
GTAW is commonly used for aerospace components, medical devices, stainless steel assemblies, aluminum components, piping systems, and precision weldments where appearance, cleanliness, and strength are important.
Resistance Welding: Fast and Repeatable Joining
Resistance welding joins materials by applying pressure and electrical current through the workpieces. Heat is generated by the material’s electrical resistance, creating a weld at the interface of the parts.
This process is commonly used for sheet metal, tabs, seams, and applications where repeatability and production speed are important.
Advantages of Resistance Welding
Fast cycle times
Repeatable process for compatible parts
No filler metal required
Well suited for certain production environments
Can be effective for sheet metal and small assemblies
Useful for spot, seam, and projection welding applications
Limitations of Resistance Welding
Best suited for specific joint designs and material stacks
Requires access for electrodes
Less flexible for complex geometries
Material thickness and conductivity affect process performance
Common Resistance Welding Applications
Resistance welding is commonly used for sheet metal components, tabs, electrical contacts, battery-related assemblies, automotive parts, and production components that require fast, repeatable joining.
How to Choose the Right Type of Welding
The right welding method depends on the requirements of the part, not just the material being welded. Before choosing a welding process, manufacturers should consider:
Material type – Some metals are more sensitive to heat, oxidation, cracking, or contamination.
Material thickness – Thin materials may benefit from laser welding, while thick sections may require electron beam welding.
Joint design – Fit-up, access, gap tolerance, and weld geometry all affect process selection.
Strength requirements – Critical parts may require deeper penetration, cleaner welds, or more controlled heat input.
Heat sensitivity – Parts with tight tolerances may require a low-distortion process.
Production volume – Manual GTAW may suit lower-volume precision work, while laser or resistance welding may support repeatable production.
Cleanliness requirements – Vacuum or inert atmosphere processing may be needed for contamination-sensitive parts.
Industry requirements – Aerospace, defense, medical, and energy applications may require stricter process control, documentation, or certification.
For general-purpose welding, many processes can join metal effectively. For high-value components where precision, strength, cleanliness, repeatability, and distortion control matter, advanced processes like laser welding, electron beam welding, GTAW, and resistance welding may be the better fit.
Which Welding Process Is Best?
There is no single best welding process for every application. The best type of welding depends on the part’s material, geometry, performance requirements, and production needs.
Laser welding is often best for fast, precise, low-distortion welds.
Electron beam welding is often best for deep, clean, high-strength welds in critical components.
GTAW/TIG welding is often best for clean, controlled, high-quality welds.
Resistance welding is often best for repeatable spot, seam, or projection welds in compatible parts.
Laser welding in a glovebox or inert atmosphere is often best when sensitive materials require additional protection from oxygen, moisture, or contamination.
At Joining Technologies, we help customers evaluate the right welding process based on material, geometry, performance requirements, production needs, and industry standards.
Work With a Leader in Advanced Welding
Choosing the right welding method can have a major impact on product quality, performance, and long-term reliability. Joining Technologies provides advanced, NADCAP accredited welding services for industries that require precision, repeatability, and technical expertise.
Our capabilities include laser welding, electron beam welding, GTAW, and resistance welding, with controlled-atmosphere capabilities available for applications that require additional protection from oxygen, moisture, or contamination.
Contact us today to discuss your project and determine which welding method is the best fit for your application.
Frequently Asked Questions About Different Types of Welding
What are the main types of welding offered by Joining Technologies?
Joining Technologies offers several advanced welding services, including laser welding, electron beam welding, gas tungsten arc welding, and resistance welding. These processes are commonly used for precision components, critical assemblies, and demanding industrial applications.
What type of welding is best for precision parts?
Laser welding, electron beam welding, and GTAW are often used for precision parts. Laser welding is a strong choice for small, thin, or delicate components. EBW is often used when deep penetration and low contamination are required. GTAW is useful when high-quality manual or semi-automated weld control is needed.
What is the difference between laser welding and electron beam welding?
Laser welding uses focused light energy and is typically performed with shielding gas or controlled atmosphere conditions. Electron beam welding uses a focused beam of electrons and is performed in a vacuum. Laser welding is often chosen for speed, precision, and automation, while EBW is often chosen for deep penetration, cleanliness, and critical high-strength welds.
Is TIG welding the same as GTAW?
Yes. TIG welding and GTAW refer to the same welding process. TIG stands for tungsten inert gas welding, while GTAW stands for gas tungsten arc welding. GTAW is the more formal industry term.
What type of welding has the least distortion?
Laser welding and electron beam welding are often selected for low-distortion applications because they use concentrated heat sources and can create narrow welds with controlled heat input. Actual distortion depends on the material, part geometry, weld design, and process parameters.
Is glovebox welding a type of welding?
Glovebox welding is better understood as a controlled-atmosphere welding setup rather than a separate welding process. For example, laser welding may be performed inside a glovebox when the material or component needs protection from oxygen, moisture, or atmospheric contamination.
When is laser welding performed in a glovebox?
Laser welding may be performed in a glovebox or inert atmosphere when the material is sensitive to oxygen, moisture, or atmospheric contamination. This approach is often used for reactive metals, sensitive assemblies, and critical components where weld cleanliness and atmosphere control are important.
EAST GRANBY, Conn., February 6, 2023 – American Cladding Technologies, a leading provider of laser metal deposition services for the past decade, has announced it will begin operating as a division of Joining Technologies. Both companies are owned by Joining Industries, Inc.
Greg Miller, President of Joining Technologies, says the decision was made in order to “streamline our operations and deliver better overall service as one company operating under a single management structure.”
This shift in operations is expected to be nearly seamless, as both companies were already sharing certain resources, including sales, marketing and quality engineering.
American Cladding Technologies (ACT) will move its equipment and staff to the Joining Industries Headquarters building at 17 Connecticut South Drive, just a quarter of a mile away from its current location at 15a International Drive. ACT will take over the space currently occupied by JT Automation, another Joining Industries company, which will move to a newly acquired property in Windsor in April 2023.
Although ACT will go forward as a division of Joining Technologies rather than a separate company, they will continue use of the American Cladding Technologies brand and website www.americancladding.com. Forthcoming web updates will establish a clearer connection to Joining Technologies.
Resistance spot welding applications go beyond the automotive industry. This article will briefly explore what resistance spot welding is, and what components can be made using this process.
Automobile manufacturers use resistance spot welding very widely, but they aren’t the only ones who can benefit from using “current” technology. This process is efficient on time and cost, and it’s environmentally sustainable. A few notable resistance spot welding applications include:
Metal frame assemblies
Steel and aluminum frames that use thin sheets of material are ideal for resistance welding. From furniture to firearms, resistance welding can achieve structural support using spot welds.
Battery manufacturing and electronics
In lieu of soldering, spot welding can attach nickel strips to battery terminals. Because less heat is used using this method, the integrity of the battery is preserved.
Gas control components
Found in semi-automatic firearms, gas systems enable automatic reloading. Some of the components that make up these systems can be resistance spot welded.
Kitchen tools
Thin metals are used in all kinds of tools and appliances for the kitchen. Cookie cutters are a great example. Others include range hoods, pot handles, and chimneys.
Wire mesh
You’ll find welded wire mesh in outdoor fences, but it’s also used in construction to reinforce concrete.
What materials can spot welded?
Thin sheets of low-carbon steel, titanium, stainless steel and aluminum are popular choices. At Joining Technologies, we’re able to weld 1.58mm aluminum, and 3mm steel.
Want to learn more about resistance spot welding applications?
With so many ways to join materials, here are our top 10 reasons to use laser welding.
1. Laser welding works with a variety of materials
Laser welding can be used to join a variety of metals, including stainless steel, nickel, titanium, Inconel, and molybdenum.
Notably, laser welding can also be performed with reflective materials, such as copper and aluminum. Joining reflective and dissimilar metals can be difficult or impossible to perform with other welding methods, but laser welding makes it significantly easier.
We use lasers to weld medical device components, including microfluidics chips and surgical equipment. If it’s small or needs to be welded in a hard-to-reach place, laser welding is the go-forward method.
3. It can also make big (deep) welds
In addition to creating microscopic welds, lasers are capable of welding thicker materials and creating structural welds that are 1/2″ deep.
4. The process and results are highly repeatable
If you totally love how your laser welded components turned out, we have good news for you: those results are repeatable. We can do it again, and again, the exact same way. This is because laser welding is…*drumroll…*
5. Laser welding is precisely controllable
For each job, our laser welding systems’ parameters are customized. With this noncontact process, we can easily control the size of the laser beam and, therefore, the size of the heat affected zone (more on that later!).
6. Unmatched speed
Laser welding can perform in minutes what TIG welding could perform in hours. The travel rate of the laser can be between hundreds and thousands of inches per minute.
7. Need low heat input? Choose laser welding.
Laser welding transmits heat in small, controlled areas. Other processes, like MIG welding, have greater heat inputs, which causes more residual stress on the component. Controlling the heat affected zone with laser welding keeps more of the metallurgical structure intact. The result is a higher quality weld that require less finishing and heat treating.
Laser welding’s-controlled heat affected zone also makes it possible for us to weld the exterior of a device without harming thermal-sensitive internal components.
8. Few size constraints on components
Laser welding can be performed in an open-air environment or in a glovebox. This opens up the possibility for working on larger components if you have a capable laser for the job.
9. Easily integrated with off-the-shelf motion products: CNC platforms, robots
Robots have been welding since 1962, and have been used more and more ever since. The road to innovating with this technology is paved and getting smarter all the time.
10. Laser welding is cost effective
Out of all 10 reasons to use laser welding, this is one of the best! You can achieve high quality results without compromising your budget. Laser welding is fast, controllable, and repeatable, making this method highly productive and efficient.
Although laser welding equipment is expensive, working with a contract manufacturer like Joining Technologies can allow you to access precision laser welding services without investing in the floor space, specialized talent, and equipment required for an in-house operation.
Laser welding firearms might be new, but firearms manufacturing in New England is something of a tradition.
In 1777, George Washington chose Springfield, MA to be our budding nation’s first arsenal. Headquartered in this region are companies steeped in the history of firearms; Smith & Wesson, Savage Arms, Sturm & Ruger, O.F. Mossberg & Sons, Colt, and countless others. Many of the United States’ first firearms manufacturers are still in operation today and continue call New England their home.
A complete supply chain has grown around these manufacturing leaders. As of May 2022, a total of 550 firearms manufacturers (FFL classes 6 – 11) exist across MA and CT. 206 of them are SOTs. You’ll find no shortage of companies, like Joining Technologies, that help produce firearms, whether it’s by forging, machining, stamping, or laser welding firearms components that become part of the final assembly.
What does it mean to be a firearms manufacturer?
Joining Technologies maintains a Code 07 Federal Firearms License. This is designated for a “manufacturer of firearms other than destructive devices.” The Code 07 FFL is separate from those possessed by dealers, importers, and antique collectors. However, anyone who is “engaging in the business of” firearms needs to acquire and maintain a license.
Joining Technologies is also a Special Occupational Taxpayer (SOT). Having an SOT expands upon the Code 07 FFL, allowing manufacturers to commercially manufacture and handle NFA items, such as suppressors. Manufacturers must also observe state laws surrounding firearms, which may further regulate working with NFA items.
Quality standards for firearms manufacturers
In addition to obtaining the proper clearances and documentation, it’s also incredibly important to adhere to quality standards when laser welding firearms. Firearms can be dangerous even when they are functioning correctly. An unsafe firearm can lead to disastrous worst-case scenarios.
After laser welding firearms components, Joining Technologies performs the following quality inspections:
Cross-section to observe the depth of penetration.
Components must pass pull and torque tests for strength.
The heat affected zone is an area of the base material that hasn’t melted during the welding process, but has undergone changes in material properties as a result of its exposure to high temperatures.
Where Does the Heat-Affected Zone Occur?
Heat affected zones form adjacent to the weld. The following factors influence the size of the HAZ:
Heat input
Duration of exposure to heat
Thermal diffusivity of the base material
Longer cooling times can contribute to a larger HAZ because the surrounding material remains exposed to elevated temperatures for a longer period. Low-heat-input laser welding can help components cool faster, reducing the size of the heat affected zone and limiting distortion in precision assemblies.
For applications that require deep penetration, high weld integrity, and minimal distortion, electron beam welding can also be an effective option. Because EBW uses a highly focused energy source in a vacuum environment, it can produce deep, narrow welds while limiting the overall heat affected zone. Learn more about our electron beam welding services for precision components and critical assemblies.
Why Does the Heat-Affected Zone Matter?
The heat-affected zone matters because exposure to welding temperatures can change the base material’s mechanical and metallurgical properties even though the material does not melt. Depending on the alloy, heat input and cooling rate, the HAZ may experience grain growth, increased or reduced hardness, lower ductility, residual stress or reduced corrosion resistance.
These changes can influence the strength, dimensional stability and long-term performance of a welded component. Controlling the HAZ is especially important for aerospace, medical, defense and other precision applications where distortion, cracking or changes in material properties could affect part performance.
How Is the Heat-Affected Zone Evaluated?
Often, heat tint is visible and can indicate the temperature the material reached. On some stainless steels, heat tint may progress from pale yellow or straw-colored tones to darker blues as thermal exposure increases. However, the relationship between color and temperature varies based on the alloy, surface condition, shielding and oxygen exposure.
However, these colors are visible because of oxidation. Factors like surface condition, contamination and oxygen availability can affect the appearance of a heat affected zone. Materials with a high amount of chromium won’t display intense heat tint, because they’re resistant to oxidation.
While the heat tint is the most visible indicator that a material has undergone change, other chemical and metallurgical changes can occur within the HAZ. They include:
Hardness changes – Welding thermal cycles can harden or soften the HAZ depending on the alloy, peak temperature and cooling rate.
Reduced corrosion resistance – In some stainless steels, chromium carbide precipitation near grain boundaries can reduce localized corrosion resistance.
Hydrogen-related cracking – Diffusible hydrogen can contribute to cracking in susceptible materials, particularly when combined with high hardness and residual stress.
Phase and microstructure changes – Rapid heating and cooling can alter the material’s microstructure. In some steels, martensite may form, increasing hardness and brittleness.
Heat tint can provide a visible indication of thermal exposure, but appearance alone does not fully define the size or condition of the HAZ. Depending on the material and application requirements, manufacturers may use visual inspection, hardness testing, metallographic examination or other qualified inspection methods to evaluate changes near the weld. The appropriate method depends on the alloy, weld specification and required component performance.
How Can the Heat-Affected Zone Be Reduced or Controlled?
A heat-affected zone cannot be eliminated from a fusion-welding process, but its size and effects can often be controlled. The appropriate strategy depends on the material, component geometry, joint design and required weld performance.
Manufacturers can manage the HAZ by controlling heat input, welding speed, beam or arc placement, joint fit-up and cooling conditions. Concentrated-energy processes such as laser welding and electron beam welding can produce narrow welds with limited overall heat input, helping reduce distortion in suitable applications. Pre-weld or post-weld heat treatment may also be used when required to manage hardness, residual stress or other metallurgical changes.
Process development should consider both the finished weld and the surrounding base material. Joining Technologies evaluates the complete application, including material, geometry, tolerances and performance requirements. This determines the appropriate welding and thermal-management strategy.
Laser welding is one of several methods available for joining metals. So, how exactly does it work? Simply put, it uses concentrated light-based energy to melt and fuse certain materials, typically metal to metal, both ferrous and non-ferrous. It was developed in the 1960’s and was initially regarded as a specialty process. Today it is commonly used in various industries for the many benefits it brings. Though traditional welding methods persist. So, how do you know if laser is the best approach for your needs? Today, we’ll look at the advantages of laser welding when compared to other welding methods.
Laser Welding vs. Popular Traditional Methods
Lasers deliver a weld with extreme precision, meaning the heat-affected zone is smaller. Also, overall heat input to the workpiece is lower when compared to gas tungsten arc welding (GTAW), brazing or other conventional methods. With GTAW, for instance, heat input is significantly higher as well as heat affected. Less heat means less unwanted distortion, and fewer damaging effects overall. GTAW is also not capable of reaching the same fusion or penetration depths of a laser weld.
When compared to resistance welding, a laser welded joint of a similar size using similar heat input is less likely to fail. A tensile test would show a higher level of strength from laser than resistance.
Laser Welding vs Electron Beam (EB) Welding
More demanding applications may be suited for either electron beam welding or laser. Though laser welding’s advantages tend to stand out here as well. When compared to EB, laser is typically 20-30% less expensive. Further, more complex solutions can be delivered since components can be welded in an open-air environment. Also, shielding of gas can be applied directly to the weld. For larger volume projects, particularly ones that grow over time, laser can be more easily brought in for vertical integration than more complex systems like those required for EB welding. For this reason and others, a typical laser installation costs less than EB overall.
It’s important to note that EB welding is performed in a vacuum chamber, which comes with certain restrictions and limitations. Conversely, laser welding is conducted in the open air. It is faster, more flexible with fixturing, and is not subject to other functional requirements associated with vacuum environments.
Small Parts Demand Precise Welds
When considering which approach is best, part size is definitely a major factor, especially when dealing with miniature and microminiature components or assemblies. The challenge with traditional approaches is that it’s harder to precisely apply gas to a smaller part. An advantage of using a laser welding system is that it can be scaled down to do micro-welding.
Also, laser welding is not an electrically conductive process; there is no interaction with the material itself. This is unlike gas tungsten arc or resistance welding, where the part might be contacted by the equipment. This could cause a multitude of a problem for batteries and other electronic equipment.
Materials
As we mentioned earlier, laser welding can be used for both ferrous and non-ferrous materials. The list of commonly joined materials includes stainless steel, titanium and other grades of steel as well as aluminum and copper.
It also excels when welding precious metals like platinum, rhenium and other refractory alloys. This is why laser welding is often employed for semiconductor and battery manufacturing, which previously relied heavily on EB welding.
Consider Laser Welding
As you can see, laser welding has several advantages over competing methods. For projects that require low heat input, high precision, and repeatable weld quality, precision laser welding services may be the right fit. Often, it is. As a result, manufacturers benefit from reduced processing time, increased weld strengths (product reliability), and the overall efficiency that laser welding delivers.
Joining Technologies offers all of the welding processes mentioned in this article! Go to our Services page to learn more, or Ask an Expert for more information!
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Joining Technologies exhibited its laser welding services for firearms at the annual Shooting, Hunting and Outdoor Trade (SHOT) Show in Las Vegas, Nevada. The event hosts not only firearms manufacturers, suppliers, and retailers, but also law enforcement, media and non-profit organizations. The show runs for a full week, packed with product showcases, networking events, industry panels, and more.
Across America, the $7.1 billion firearms industry supports more than 342,000 jobs. Perhaps it’s no surprise that the SHOT Show is the 5th largest tradeshow in Las Vegas. The show brings around $88 million in non-gambling revenue to the city. This year’s event was the largest hosted by The Venetian Expo in the two years since the COVID-19 pandemic began. Coupled with the “All In” theme of this year’s show, the message was clear: business is back.
SHOT Show 2022 Supplier Showcase - January 17 and 18, Venetian Expo, Las Vegas
Behind the 2,400 firearms and defense exhibitors at the 2022 SHOT Show are suppliers that help produce and elevate product lines. The SHOT Show Supplier Showcase is where you’ll find partners in machining, textiles, optics, and of course, laser welding for firearms.
Among the 556 suppliers at this year’s showcase, Joining Technologies was the sole partner for contract laser welding. To many who visited our booth on the show floor, it was an intriguing option they’d never before considered. While welding itself obviously isn’t unheard of, introducing the idea of welding with laser technology definitely sparks a conversation. Attendees were eager to learn how we might fit into their supply chain, or bring their production to the next level.
Among our techniques for firearms welding, laser welding is an ideal choice for safety assemblies and delicate components. Laser welding can also be used to weld suppressors and magazines. We use resistance welding for stocks, gas tubes, and other structural parts of a firearm. Beyond delivering quality, precision welded components, our contract manufacturing program is ideal for manufacturers growing a new product line or looking to save money and time by partnering with an outside expert in firearms welding.
SHOT Show 2022 (Main) - January 18 - 21 Venetian Expo & Caesars Forum, Las Vegas
The SHOT Show extended far beyond the Supplier Showcase. With 13.9 miles of aisles across the Venetian Expo and Caesars Forum, the event drew 43,000 attendees. Being an exhibitor was a fantastic opportunity to connect directly with members of the firearms industry. We talked with owners of businesses big and small, old and new. We also met engineers, purchasers, gunsmiths, shooting coaches, law enforcement officers – all connected to the firearms industry in some way. It was truly amazing just how many purposes were represented in one place. We found it was especially rewarding to visit the exhibiting manufacturers and suppliers, some of whom currently use laser welding for firearms. Seeing the products we help develop on display at the show was especially a treat.
Beyond the SHOT Show
Although it was impossible to see absolutely everything, what we did see left us in awe. We gained new perspective of how large the firearms industry is and who operates within it. We also witnessed the results of industry growth. Between 2020 and 2021, 40 million background checks were conducted in relation to firearm sales, and more than 11 million Americans purchased a firearm for the first time either for sport, hunting or personal security. This trend bodes well for 2022 as interest grows in the culture of shooting sports, gun ownership and personal safety. As warehouse stocks replenish and Americans purchase their first firearms, Shooting Industry Magazine predicts that retailers will play a key role in maintaining growth.
“The savvy retailer will remain in contact with first-time owners, encouraging them to visit a range and helping them become competent, comfortable users. Otherwise, our growth in the past two years will be just a bump on our long-term trend charts. It’s up to all of us, as an industry, to help these new gun owners and ensure they become an active consumer/participant at the range and in the store.”
We have to admit, it’s exciting to bring laser welding to a growing industry! Want to learn more about the services we offer? Explore our Precision Welding Services page for information on laser welding, resistance welding, electron beam welding, and more.
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