The Process

Hybrid laser arc welding process

Hybrid laser welding process
1 Newly formed weld bead
2 Inert shielding gas
3 Focused laser beam
4 GMAW torch
5 Wire electrode
6 Electric arc
7 Molten pool
8 Keyhole

Graphic illustrating differences between GMAW, Laser and HLAW weld profiles

Graphic illustrating differences between GMAW,
Laser and Hybrid Laser Welding weld profiles

Duplex Stainless

Duplex Stainless

Full-Pen Fillet

Full-Pen Fillet

What’s new about Hybrio™ technology?

ESAB’s Hybrio™ hybrid laser welding technology combines the deep weld penetration and low heat input associated with laser welding with the excellent weld properties and superior gap tolerance of Gas Metal Arc Welding (GMAW). A radically new welding alternative, it produces extremely narrow and deep welds at very high travel speeds. In a single pass, the Hybrio™ process can often achieve what might require multiple weld passes using a conventional fusion welding process. Heat input to the part is reduced, as is the associated weld shrinkage and distortion that can make post-welding geometry unpredictable – and costly to repair.

Using GMAW in combination with a laser, the Hybrio™ process solves laser-only welding’s limitations, concerning its ability to produce acceptable welds in joints with less than perfect fit-up between parts. This enables a widened, more robust process envelope by a factor of three compared to a conventional laser-only process. GMAW also allows users to add filler metal to adjust the weld’s metallurgical properties and create beads and fillets, while the slower cooling rate reduces hardness. These features are especially beneficial when joining high performance carbon and stainless steels.






Characteristics of Hybrid Laser welds

Ten years of development and testing that ESAB and our partners have conducted on the Hybrid Laser Welding process have conclusively proven that hybrid welds can be at least as strong, tough and ductile as conventional welds in every way. In some ways hybrid welds can be superior to conventional welds. The very fine grain structures and smooth, uniform welds resulting from the low heat input make hybrid welds exceptionally good for high performance alloys. The very smooth, consistent Hybrid Laser Welding welds have been demonstrated to improve fatigue limits on fillet welds by a 300% over similarly sized conventional welds.