1. BODY ASSEMBLY PROCESS
LASER WELDING VS SPOT WELDING
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2. AUTOMOTIVE LASER WELDING
LASER WELDING COMPARISON
Process Type
Laser Type
Application
Area
Advantages
Disadvantages
Remarks
Single Sided Process
CO2
- High Power (6
kW)
Nd:YAG
- Low Power (4
Butt / Edge joint
(brazing applications)
Lap joint
TWB – Door inner
panels
Roof to side structure
Sub assembly process
Closure hemming
flange
Good weld
accessibility (Single Side
Process)
Reduced width of -
or elimination of -
the flange, resulting
in reduced vehicle
weight.
Low operational cost
Panel gap constraint
(no clamping force)
Narrow penetration
(nugget)
Tighter parts &
assembly tolerance
Worse corrosion risk vs
spot welding
High price
Jig / fixtures
needed for
clamping / support
to eliminate panel
gap
Suitable as
MIG welding (eg
CO2) alternatives
Double Sided Process
Laser Seam
Stepper (LSS)
- Low Power (2
Respot process
Higher process
speed (shorter cycle
times)
Increased component
strength by longer
seams with higher
torsional stiffness
‘Build in’ clamping
force function
(eliminate panel gap)
Low operation cost
Weld point
accessibility same as
spot welding gun
Suitable as spot
welding
alternatives
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3. AUTOMOTIVE LASER WELDING
COST COMPARISON
Estimated Cost
Resistance Spot Welding
GMAW (Mix Ag/CO2) Welding
Laser Welding
Single Sided Process
Double Sided Process
Welding Equipment per set
RM 50k to 70k
RM 60k to 70k
RM 1.2Mil (4kW)
No Information
Cost per Spot
Servo / Trans Gun – 70kW
Robot : RM
Robot : RM / 10mm length
Total : RM / 25mm length
Total : RM / 30mm length
*Equivalent to 3 spot
welding
Pneumatic Gun – 150kW
Manual : RM 0.073
Manual : RM / 10mm length
*Note : Please refer to calculation table on “Reference” section
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WELDING EQUIVALENT APPROXIMATION
Resistance Spot Welding
GMAW (Mix Ag/CO2) Welding
Laser Welding
Remarks
Single Sided Process
Double Sided Process
1 spot (general) = 4√tmin (Ø)
10mm (length)
18 ~ 25mm (length)
*Straight pattern
30mm / LSS
*Equivalent to 3 spot welding
* Zig-zag pattern
Reference :
i. Single Sided Process : Volvo practice
ii. Double Sided Process : Photonics.com

4. REFERENCES
LASER WELDING VS SPOT WELDING
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5. AUTOMOTIVE LASER WELDING
COSTING CALCULATION
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6. AUTOMOTIVE LASER WELDING
GENERAL GUIDANCE
CO2 Laser
Nd : YAG Laser
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