Laser welding without filler wire opens up new applications
Advances for vehicle construction, aviation and the steel industry
Researchers at Fraunhofer IWS show that metals can be welded precisely and stably with dynamically shaped laser beams, even without additional wire.
Laser processes with dynamic beam shaping enable stable joints in difficult material combinations. New applications show how filler materials can be dispensed with while simultaneously increasing quality and energy efficiency. At the ‘Welding & Cutting 2025’ trade fair, Fraunhofer IWS presented solutions for lightweight construction in e-mobility, tank structures in aviation and load-bearing steel components.
Several projects rely on a specifically moved beam that actively influences the molten pool, thus allowing the joining of difficult-to-weld alloys or large cross-sections. High-frequency scanner technology, flexible power control and an open-system control system expand the design possibilities.
Solutions for many industries
In the EU project ALBATROSS, the IWS manufactured a battery housing from extruded aluminium profiles and die-cast parts without additional wire. The oscillating beam guidance reduces pores and produces stable seams. The process is being further developed in the ‘FutureCarProduction’ flagship project.
For the aerospace industry, the IWS developed low-heat laser welding of high-strength 2000 series alloys without filler material – even on 3D contours. The BMWK-funded process delivers dense, low-distortion seams.
For steel construction, a multi-layer welding process with up to 24 kW laser power was developed. Optimised V-seams reduce the seam volume, save up to 90 percent of filler material and significantly reduce distortion.
The demonstrators on display showed how materials science expertise, process engineering experience and systemic implementation can be successfully combined.
