Welding Digest

Handheld laser welding (HHLW) systems have garnered significant interest in the welding industry due to their high productivity, ease of setup and use, reduced training requirements, and lower cost. As with any new technology, ensuring proper safety measures is crucial, particularly due to the unique hazards associated with laser radiation and equipment use.

The advantages of HHLW help alleviate some of the pressure brought on by the industry’s skilled labor gap. Some systems are claimed to weld up to four times faster than gas tungsten arc welding, requiring minimal material preparation and postfinishing. Other benefits of HHLW include higher throughput, less postweld work due to the lower heat input, and the ability to employ less-experienced personnel. However, these personnel still need to be qualified, especially regarding safety, to mitigate the hazards of laser radiation.

The recent proliferation of HHLW systems worldwide has highlighted the lack of clear and concise safety guidance. More specifically, the industry needs safety precautions and requirements for the HHLW process. This need drove the AWS Safety and Health Committee (SHC) and the AWS SH4 Subcommittee on Labeling and Safe Practices to undertake a project to author the new AWS Safety and Health Fact Sheet on HHLW Safety (AWS FS #46, available as a free download at aws.org/standards-and-publications/free-resources).

Welding personnel should be familiar with the essential safety precautions, including those related to electrical hazards, fumes and gases, fire and explosion risks, burns, arc rays, noise, and electric and magnetic fields. HHLW systems introduce the new hazards of laser beams and laser radiation. Therefore, the focus of the hazard information in the new AWS FS #46 is on the following areas: the nature of laser hazards, eye hazards, skin hazards, and reflection hazards. Additionally, the FS provides information on how to reduce exposure to hazards. This section details the important built-in safety features of HHLW equipment along with the requirements for a laser-controlled area for each point of use and a laser safety officer within each organization who is responsible for the safety of operators and observers. Lastly, the FS provides a list of information sources regarding lasers, HHLW, and welding safety.

A major difference between most welding processes and the HHLW process is the use of the welding helmet. Standard welding helmets and standard safety eyewear do not provide adequate protection from laser beam hazards. Therefore, welding personnel must wear laser safety eyewear and a laser welding helmet when using HHLW systems. If the laser welding helmet has integrated eye protection (integrated seal), then the laser welding helmet alone is adequate. When welding personnel use both laser and arc welding processes, it is recommended to use a hybrid style of welding helmet.

The overall goal of this project is to educate the welding industry on the necessary safety precautions to mitigate the new laser beam and laser radiation hazards introduced by HHLW systems into the welding environment while realizing the wide range of benefits from the system. I encourage everyone interested in HHLW systems to visit the previously listed link to the new AWS Safety and Health Fact Sheet #46.