Veerya Attachments Pvt. Ltd. (India) submitted a request for a handheld fiber laser welding machine for their production line welding CAT attachment components. The components are fabricated from carbon steel ST52.3 (S355J2 equivalent) and low-alloy wear-resistant steel HB500. The application demands deep penetration, high weld strength, and minimal distortion on thick-section attachments subjected to severe service conditions.
The inquiry specified three laser power options—3 kW, 4 kW, and 6 kW—to be quoted separately. Key technical requirements include a wobble/swing-type welding head for gap bridging, an automatic wire feeder for 0.8–1.2 mm welding wire, a 10–15 meter fiber cable for shop-floor maneuverability, and a 415 V, 3-phase, 50 Hz power supply suitable for India. The customer also requested detailed technical datasheets, a 2-year spare parts list, CE/IEC certifications, and information on after-sales support availability in India.
Process Analysis: Why Handheld Fiber Laser Welding for Heavy Attachments
The CAT attachment components manufactured by Veerya Attachments are large, heavy fabrications—brackets, mounting plates, reinforcement ribs, and structural weldments—where traditional MIG welding is the incumbent process. MIG welding on ST52.3 and HB500 presents three challenges that handheld laser welding directly addresses:
- Heat input and distortion. MIG welding deposits 300–500 J/mm of heat, producing significant thermal distortion on long seams and requiring post-weld straightening. A fiber laser operating in conduction or keyhole mode delivers 25–60 J/mm, reducing the heat-affected zone width from 4–8 mm to 0.5–1.5 mm. Distortion is eliminated.
- Filler metal consumption and grinding. MIG welds on HB500 wear plate require multiple passes and generate heavy reinforcement that must be ground flush. A laser weld with an oscillating (wobble) head bridges gaps up to 1.5 mm in a single pass, with a smooth, flat bead profile that requires minimal post-weld finishing.
- Operator skill dependency. Certified MIG welders are scarce and command high wages. A handheld laser welding gun with a preloaded parameter library and wire feed synchronization enables a semi-skilled operator to produce consistent, high-quality welds after 3–5 days of training.
The wobble welding head is the critical enabler for this application. It oscillates the focused beam in a circular or linear pattern at frequencies up to 300 Hz, widening the weld pool and allowing it to bridge joint gaps that would cause a static laser spot to miss one side of the joint entirely. For CAT attachment components fabricated from flame-cut or plasma-cut plates with typical fit-up gaps of 0.5–1.5 mm, the wobble function eliminates the need for precision edge preparation.
Recommended Equipment Configurations (3 kW / 4 kW / 6 kW)
YIHAI LASER offers three power configurations of the YW-HH series handheld fiber laser welding system. All configurations share the same platform architecture—laser source, water chiller, handheld welding gun, wire feeder, and control unit—and differ only in laser power and associated cooling and electrical requirements. The table below provides the technical specifications for each configuration.
| Specification | YW-HH-3000 (3 kW) | YW-HH-4000 (4 kW) | YW-HH-6000 (6 kW) |
|---|---|---|---|
| Laser type | Continuous Wave (CW) Fiber Laser | Continuous Wave (CW) Fiber Laser | Continuous Wave (CW) Fiber Laser |
| Laser source make & model | Maxphotonics MFSC-3000 (single-mode) | Maxphotonics MFSC-4000 (single-mode) | Maxphotonics MFSC-6000 (single-mode) |
| Rated output power | 3,000 W | 4,000 W | 6,000 W |
| Wavelength | 1,070 ± 10 nm | 1,070 ± 10 nm | 1,070 ± 10 nm |
| Beam quality (BPP) | ≤ 0.4 mm·mrad | ≤ 0.4 mm·mrad | ≤ 0.4 mm·mrad |
| Power stability | ± 1.5% | ± 1.5% | ± 1.5% |
| Welding head make & model | WSX Wobble Welding Head, ND Series | WSX Wobble Welding Head, ND Series | WSX Wobble Welding Head, ND Series |
| Wobble frequency | 0–300 Hz | 0–300 Hz | 0–300 Hz |
| Wobble pattern | Circular, linear, figure-8 | Circular, linear, figure-8 | Circular, linear, figure-8 |
| Fiber cable length | 15 meters (standard) | 15 meters (standard) | 15 meters (standard) |
| Wire feeder make & model | WSX AF-01 Automatic Wire Feeder | WSX AF-01 Automatic Wire Feeder | WSX AF-01 Automatic Wire Feeder |
| Compatible wire diameters | 0.8 / 1.0 / 1.2 mm | 0.8 / 1.0 / 1.2 mm | 0.8 / 1.0 / 1.2 mm |
| Cooling system make & model | S&A CW-6200 Industrial Water Chiller | S&A CW-6300 Industrial Water Chiller | S&A CW-6500 Industrial Water Chiller |
| Chiller temperature stability | ± 0.5°C | ± 0.5°C | ± 0.5°C |
| Chiller cooling capacity | 6.0 kW | 10.0 kW | 16.0 kW |
| Power supply | 415 V, 3-phase, 50 Hz | 415 V, 3-phase, 50 Hz | 415 V, 3-phase, 50 Hz |
| Total power consumption | 12 kVA | 16 kVA | 22 kVA |
| Machine dimensions (laser + chiller cabinet) | 1,100 × 700 × 1,200 mm | 1,100 × 700 × 1,200 mm | 1,200 × 800 × 1,300 mm |
| Total machine weight | 280 kg | 320 kg | 380 kg |
| Operating environment temperature | 10–40°C | 10–40°C | 10–40°C |
| Operating environment humidity | ≤ 80% RH (non-condensing) | ≤ 80% RH (non-condensing) | ≤ 80% RH (non-condensing) |
| Laser safety classification | Class 4 (IEC 60825-1) | Class 4 (IEC 60825-1) | Class 4 (IEC 60825-1) |
| Safety features | Key switch, emergency stop, interlocks, laser safety goggles included | Key switch, emergency stop, interlocks, laser safety goggles included | Key switch, emergency stop, interlocks, laser safety goggles included |
| Certifications | CE, IEC 60825-1, ISO 9001 | CE, IEC 60825-1, ISO 9001 | CE, IEC 60825-1, ISO 9001 |
| Warranty | 24 months (laser source and machine) | 24 months (laser source and machine) | 24 months (laser source and machine) |
Material-Specific Welding Performance
The tables below provide the maximum recommended single-pass welding thickness, recommended welding speed, wire specifications, and penetration data for ST52.3 carbon steel and HB500 low-alloy wear-resistant steel. Values are based on production trials conducted in YIHAI LASER’s application laboratory using the specified Maxphotonics laser sources and WSX wobble welding head.
ST52.3 Carbon Steel (S355J2 Equivalent)
| Parameter | 3 kW Configuration | 4 kW Configuration | 6 kW Configuration |
|---|---|---|---|
| Max. single-pass penetration depth | 4.0 mm | 5.5 mm | 8.0 mm |
| Max. recommended welding thickness (multi-pass) | 6.0 mm | 8.0 mm | 12.0 mm |
| Recommended welding speed (3 mm plate, fillet weld) | 1.2 m/min | 1.6 m/min | 2.2 m/min |
| Recommended welding speed (5 mm plate, butt weld) | 0.8 m/min | 1.1 m/min | 1.5 m/min |
| Recommended filler wire | ER70S-6, 1.0 mm diameter | ER70S-6, 1.0 mm or 1.2 mm diameter | ER70S-6, 1.2 mm diameter |
| Shield gas | Argon (99.99%), 12–15 L/min | Argon (99.99%), 15–18 L/min | Argon (99.99%), 15–20 L/min |
| Wobble pattern | Circular, 2.0 mm width | Circular, 2.5 mm width | Circular, 3.0 mm width |
| Wobble frequency | 80 Hz | 100 Hz | 120 Hz |
| Weld quality | Smooth, flat bead, no spatter | Smooth, flat bead, no spatter | Smooth, flat bead, no spatter |
| Tensile strength (as-welded) | ≥ 520 MPa (overmatch) | ≥ 520 MPa (overmatch) | ≥ 520 MPa (overmatch) |
HB500 Low-Alloy Wear-Resistant Steel
| Parameter | 3 kW Configuration | 4 kW Configuration | 6 kW Configuration |
|---|---|---|---|
| Max. single-pass penetration depth | 3.5 mm | 5.0 mm | 7.0 mm |
| Max. recommended welding thickness (multi-pass) | 5.0 mm | 7.0 mm | 10.0 mm |
| Recommended welding speed (4 mm plate, fillet weld) | 0.9 m/min | 1.2 m/min | 1.7 m/min |
| Recommended welding speed (6 mm plate, butt weld) | 0.6 m/min | 0.9 m/min | 1.2 m/min |
| Recommended filler wire | ER80S-G or ER100S-G, 1.0 mm | ER80S-G or ER100S-G, 1.0 mm | ER100S-G, 1.2 mm |
| Preheat requirement | None for thickness ≤ 5 mm; 100–150°C for 5–8 mm; 150–200°C for >8 mm | ||
| Shield gas | Argon (99.99%), 12–15 L/min | Argon (99.99%), 15–18 L/min | Argon (99.99%), 15–20 L/min |
| Wobble pattern | Circular, 2.0 mm width | Circular, 2.5 mm width | Circular, 3.0 mm width |
| Wobble frequency | 80 Hz | 100 Hz | 120 Hz |
| Weld quality | Crack-free, low hydrogen, no undercut | Crack-free, low hydrogen, no undercut | Crack-free, low hydrogen, no undercut |
| Hardness in HAZ | Maintained within 90% of base metal | Maintained within 90% of base metal | Maintained within 90% of base metal |
Power Selection Recommendation
YIHAI LASER recommends the following selection logic based on the dominant material thickness in Veerya Attachments’ production:
- 3 kW (YW-HH-3000): Suitable if the majority of welds are on plate thicknesses ≤ 4 mm for ST52.3 and ≤ 3.5 mm for HB500. This configuration provides the lowest capital cost and is adequate for thin-gauge attachment brackets and covers.
- 4 kW (YW-HH-4000): Recommended for mixed production with plate thicknesses up to 5.5 mm ST52.3 / 5.0 mm HB500 in single pass. Provides a 30–35% speed increase over 3 kW on common thicknesses and sufficient capacity for the majority of CAT attachment components.
- 6 kW (YW-HH-6000): Recommended if Veerya Attachments regularly welds plates of 8–12 mm thickness, where the 6 kW source enables single-pass welding without multi-pass cycles. The higher power significantly increases productivity on thick sections and provides the deepest penetration capability.
Consumables and Recommended 2-Year Spare Parts
| Spare Part | Quantity (2-Year, Single-Shift) | Unit Price (USD, indicative) |
|---|---|---|
| Protective lens (welding head) | 20 pcs | $15 |
| Nozzle tip (welding gun) | 10 pcs | $12 |
| Ceramic ring | 5 pcs | $8 |
| Wire feed liner (0.8–1.2 mm) | 4 pcs | $25 |
| Wire feed drive roller set | 2 sets | $45 |
| Fiber cable protective sleeve | 2 pcs | $60 |
| Chiller filter cartridge | 4 pcs | $18 |
| Laser safety goggles (OD 6+ @ 1070 nm) | 4 pcs | $85 |
| Welding gun switch assembly | 2 pcs | $35 |
| O-ring kit (water connectors) | 2 kits | $20 |
All consumable parts are stocked at YIHAI LASER’s regional distributor warehouse in India (Mumbai and Chennai) and are available for 48-hour dispatch.
After-Sales Service and Technical Support in India
YIHAI LASER maintains a technical support network in India through authorized distributors in Mumbai, Chennai, Bengaluru, and Delhi. Service capabilities include:
- Remote support: 24-hour response via video call from YIHAI LASER application engineers.
- On-site service: Technician dispatched within 48 hours for critical faults.
- Spare parts availability: Consumables stocked in India; major components (laser source, chiller compressor) available within 7–10 working days from the Singapore regional hub.
- Annual maintenance contract (AMC): Available optionally; includes two preventive maintenance visits per year, laser power calibration, and chiller coolant replacement.
Installation, Commissioning, and Training
YIHAI LASER’s standard installation and training package for India includes:
- Installation and commissioning: A YIHAI LASER service engineer travels to Veerya Attachments’ facility for 3 days. Activities include machine uncrating, electrical connection, chiller setup, gas line connection, welding gun assembly, and full system test.
- Operator training: 3 days of hands-on training for up to 4 operators. Curriculum covers laser safety, welding gun handling, parameter selection from the preloaded library, wire feeder setup, wobble pattern selection, and basic troubleshooting.
- Maintenance training: 1 day for maintenance personnel. Covers protective lens replacement, nozzle cleaning, chiller filter changes, and diagnostic fault code interpretation.
- Documentation: Operation manual, maintenance manual, and welding parameter library delivered in English (printed and digital).
Delivery, Payment Terms, and CIF Pricing
| Term | Detail |
|---|---|
| Production lead time | 25 working days from order confirmation and receipt of payment |
| Sea freight | 18–22 days FOB Shanghai to CIF Chennai / Bengaluru |
| Total delivery | 6–7 weeks |
| Payment terms | 30% advance with order, 70% before shipment (T/T) |
| FOB China and CIF Chennai/Bengaluru pricing | Provided separately in the formal commercial quotation |
| Pricing validity | 30 days from the date of quotation |
A formal commercial quotation with detailed FOB and CIF pricing for each power configuration (3 kW, 4 kW, 6 kW), including the 2-year spare parts list and optional fume extraction unit, will be sent separately.
YIHAI LASER Application Note
YIHAI LASER offers to weld sample ST52.3 and HB500 steel coupons provided by Veerya Attachments at no charge. The samples would be welded with the recommended parameters, and a full process report—including cross-sectional micrographs, penetration depth measurements, hardness traverses across the HAZ, and tensile test data—would be returned with the quotation. This enables Veerya Attachments to validate the weld quality against their CAT attachment specifications before making a purchase decision.
Frequently Asked Questions
What laser power is recommended for welding CAT attachment components?
3 kW is sufficient for plates up to 4 mm ST52.3 and 3.5 mm HB500. 4 kW is recommended as the optimal balance for mixed production with plates up to 5.5 mm. 6 kW is recommended for regular welding of thick plates (8–12 mm) where single-pass penetration is required. YIHAI LASER quotes all three options separately so that Veerya Attachments can select based on their dominant material thickness range.
Can a handheld laser welder weld high-strength HB500 steel without cracking?
Yes, with appropriate filler wire selection (ER80S-G or ER100S-G) and preheat for thicknesses above 5 mm. The laser’s low heat input minimizes hydrogen pickup and the narrow HAZ limits hardness drop. Weld procedure qualification tests conducted in YIHAI LASER’s application laboratory show crack-free welds on HB500 with hardness maintained at 90% or more of the base metal value.
Is the wobble welding head necessary for this application?
Yes. The wobble head oscillates the beam to widen the weld pool, bridging joint gaps up to 1.5 mm that are typical in flame-cut or plasma-cut components. It also produces a smooth, flat bead profile that requires minimal grinding, which is critical for CAT attachment components where fatigue performance depends on weld surface condition.
Does YIHAI LASER provide after-sales support in India?
Yes. YIHAI LASER has authorized distributors in Mumbai, Chennai, Bengaluru, and Delhi who stock consumables and spare parts. On-site service is available within 48 hours. Remote technical support is provided within 24 hours. An annual maintenance contract (AMC) is available for preventive maintenance and laser power calibration.
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