In the modern manufacturing landscape, industries like construction, shipbuilding, rail transit, and heavy machinery are demanding faster, cleaner, and more precise welding technologies. Traditional arc welding often falls short—especially when dealing with thick plates, complex geometries, or high-strength materials.
Hybrid laser-arc welding has emerged as a breakthrough solution, combining the deep penetration and precision of laser welding with the stability and formability of arc welding. Together, they create a synergistic process that delivers superior weld quality, higher efficiency, and lower heat distortion.
How Hybrid Laser-Arc Welding Works
This advanced process synchronizes a high-energy laser beam with an electric arc to act on the same molten pool.
- Laser energy ensures deep fusion and narrow heat-affected zones.
- Arc energy stabilizes the pool and smooths the bead formation.
The result: single-pass welding on thick sections without beveling, reduced filler material, and exceptional structural strength—ideal for demanding industrial sectors.
Customer Success Stories Across Key Industries
1.Steel Structure Manufacturing — Faster, Straighter, and Stronger
A leading steel structure manufacturer faced challenges welding 20mm-thick T-beams and I-beams. Conventional arc welding caused excessive deformation and low efficiency.
Han’s Laser delivered a dual-head hybrid laser-arc welding system equipped with two 10 kW laser sources. Each head operates simultaneously on both sides of the beam, achieving:
- Welding speeds up to 1.2 m/min
- Minimal distortion and perfect bead symmetry
- Full-penetration welds without beveling
This all-in-one system supports multiple welding modes (autogenous, filler, hybrid, arc-only), allowing flexible production changeovers. The customer reported a 40% reduction in production cycle time and a 25% improvement in overall structural accuracy.
2.Rail Transit — Precision Welding for Lightweight Car Bodies
In the rail transit sector, manufacturers must weld large stainless steel and aluminum panels for train carriages with both structural integrity and aesthetic quality.
Han’s Laser developed a gantry-type hybrid laser-arc welding workstation featuring:
- 8m × 3m working envelope
- ±05mm repeatability
- 6-axis motion with real-time tracking
The hybrid process allows high-speed welding of curved panels with excellent surface finish and minimal post-polishing.
A major metro train manufacturer integrated this system into its automated line and achieved consistent weld quality across hundreds of large carbody panels, ensuring compliance with international rail safety standards.
3.Shipbuilding — Deep-Penetration Welding for Large Hull Sections
In shipbuilding, thick plates (over 100mm) and long weld seams are common. Traditional multi-pass welding is slow and prone to distortion.
To overcome this, Han’s Laser provided a robotic hybrid laser-arc system with a 7th-axis floor rail for large-scale motion.
The system enables:
- Dual-sided hybrid welding up to 115mm thickness
- Single-sided narrow-gap welding up to 58mm depth
- Low-deformation and uniform fusion
The solution allowed a shipyard client to cut welding time by nearly 50% on hull and bulkhead sections while maintaining impeccable sealing performance for marine environments.
4.Construction Machinery — High-Efficiency Tube and Boom Welding
For construction equipment like excavators and cranes, the structural booms and arms require high-strength welds with precise alignment.
Han’s Laser engineered an inverted-gantry robotic hybrid welding station with head-tail positioners for ±180° rotation and automated clamping.
Key results for the customer included:
- Double the welding speed compared to arc welding
- 50% less deformation
- Full-penetration single-pass seams with clean bead formation
This flexible workstation reduced the customer’s fixture setup time and enabled mixed-model production on the same line—greatly enhancing throughput and process efficiency.
Driving Manufacturing Excellence Through Innovation
From the steel frames of skyscrapers to the hulls of ocean-going vessels, from rail cars to heavy machinery, hybrid laser-arc welding delivers higher efficiency and precision across modern industrial manufacturing.
Its combination of deep penetration, speed, and precision enables manufacturers to meet the ever-rising demands for quality and efficiency.
Han’s Laser continues to refine hybrid welding technologies and deliver customized solutions that empower global manufacturers to achieve smarter, cleaner, and more reliable production.