Troubleshooting Laser Welds

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Course Overview

This course focuses on laser weld defects, how to identify them, and how to troubleshoot and eliminate them from your welding process to maximize productivity.

Who Should Attend?

  • Manufacturing engineers
  • Production engineers
  • Mechanical engineers
  • Design engineers
  • R&D engineers 
  • Production, maintenance, and setup personnel
  • Laser operators
  • Quality assurance engineers
  • Laser system integrators

Additional Information

Please Note:

  1. Class size is limited due to the interactive nature of this exercise.
  2. Since this course builds upon the knowledge gained in Laser Welding: Mastering the Technology, you must have completed it prior to participating in this course.

Course Outline

Welcome and Introduction

Laser Safety

  • Laser classification
  • Beam hazards
    • eye and skin hazard
  • Non-beam hazards
    • electrical
    • chemical
    • fire
    • explosion
  • Control measures
  • Safe operation
    • eye and skin protection 

Laser Weld Defects

  • Nomenclature of weld defects
  • Product impact
  • Cost impact

How to Identify Laser Weld Defects

  • Destructive testing
  • Non-destructive testing

Root Causes of Laser Weld Defects

  • Material
  • Laser parameters
  • Equipment set-up and tooling

Methods to Reduce/Eliminate Laser Weld Defects

  • Laser weld profile measurements
    • micrographs
    • cross-sectioning
    • measurement methods and equipment
  • Troubleshooting techniques
    • optics
    • precision measurement
    • weld profile tell-tale
  • SPC for laser welds
    • program set up
    • auditing control
    • reaction to SPC

Laser Adjustments for Defects

  • Power
  • Optics
  • Specifications
  • Cosmetic enhancements
    • shield gas
    • focusing optics
    • equipment set-up

Development of Product Weld Specifications

  • Design engineering
  • Quality assurance
  • Maintaining weld specifications

Course Exercise: Micrograph Cross-Section Measurement

Laser Weld System Overview

  • Discuss current best practices


"This course was very beneficial, putting together real-world examples and troubleshooting."
Welding Engineer

"It was great that laser welding was approached as a 'system' and not just a laser…it's the tooling, parts, gas, exhaust, etc. A lot of variables to monitor and control. I realize that we need to standardize our approach to troubleshooting laser welds."
Welding Engineer

"This course provided the "control" aspect of our new laser weld process. The course provided the terminology, insight, and new ideas I needed, while clearly defining the process variables that need to be measured, specified, and controlled."
Operations Manager


Marc Hernandez

Marc Hernandez, LWP, is the Manufacturing Engineering Technician Supervisor for DSSA-AZ (Daicel Safety Systems America–Arizona), a leading initiator device manufacturer, located in Mesa, Arizona. Prior to joining DSSA-AZ, Hernandez worked as a Manufacturing Engineer at Special Devices Inc. (SDI), where he developed and maintained robotic laser welding cells for their operations worldwide. Prior to joining SDI, Hernandez worked for TRW Automotive Air Bag Inflator Manufacturing, and the US Navy in a variety of laser welding and directed energy operations.

Elaine Andrysick

Elaine M. Andrysick, joined Interdisciplinary Professional Programs, University of Wisconsin-Madison, as a continuing engineering education specialist in 1988.  She is responsible for the development and delivery of high-value continuing engineering education short courses for practicing professionals in the areas of chemical and process engineering and laser material processing.  Also, she manages the University’s Laser Welding Certificate program.

Upcoming dates (0)

Take this course when it’s offered next!

Program Director

Elaine Andrysick

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