Join Jonathan and Alex for a new episode of ALPHA Welder! In this video, we showcase the laser welding repair of a worn impeller, focusing on a deep inside diameter (ID) buildup using the ALFLAK 1200 fiber laser, paired with turn & tilt optics and the AL-DV wire feeding system.

The challenge? A 4.5″ diameter hole over 6″ deep that requires precise welding from both sides. The solution? High-precision laser buildup in multiple layers (60 thou per side), maintaining part integrity and avoiding distortion.

Benefits:

• Deep and accurate welds even in hard-to-reach areas.
• Minimal heat input = reduced risk of cracking or warping.
• Clean, repeatable results with minimal post-processing.
• Visual real-time control and fine-tuned pulse settings (21 Hz).

This episode covers:

• Multi-layer wire welding inside small-diameter components.
• Smart handling with 180° part rotation for full access.
• Consistent process development using certified WPS procedures.
• Real-world repair strategies with measurable results.

Discover how laser welding is revolutionizing repair work in the industrial sector—saving time, reducing cost, and preserving critical components.

Injection molds are the backbone of countless manufacturing operations. When they fail, production grinds to a halt, leading to costly delays and lost revenue. That’s why efficient, precise, and reliable mold repair is paramount. At Alpha Laser, we understand these critical needs, and our ALFlak laser welding system is engineered to put you back in production faster, with unparalleled accuracy. Designed for versatility and ease of use, it empowers mold makers to achieve previously unattainable levels of precision.

Key Features that Make the ALFlak Stand Out:

• 360° Swivel Head: This innovative feature allows for unparalleled access to complex geometries and hard-to-reach areas within the mold, minimizing the need for extensive mold disassembly.
• Intuitive Joystick Control: With a single toggle for X, Y, and Z-axis movement, the joystick provides precise, ergonomic control, allowing for smooth and accurate positioning of the weld spot.
• Foot Pedal Parameter Control: Keep your hands free for fine manipulation. All essential welding parameters are conveniently controlled via a robust foot pedal, streamlining your workflow and enhancing efficiency.
• Variety of Wattage Options: The Nd:YAG option comes in 200 or 300w power sources. The fiber laser comes in 300, 450, 600, 900 & 1200w power sources.

Real-World Precision: A Stainless Steel Mold Repair Example

Let’s illustrate the ALFlak’s capabilities with a common scenario: a design change on a stainless steel injection mold component.

The Need: A design modification required all sidewalls up to the parting line to be shifted inward by a precise 0.025 inches. This type of repair demands extreme accuracy to ensure the integrity and functionality of the final molded part.

The Result: A perfectly executed design change, with the sidewalls precisely shifted inward by 0.025 inches, ready for subsequent machining and finishing. The ALFlak’s precision ensured that the structural integrity and surface finish of the mold were maintained, leading to a high-quality, functional component.

Invest in Precision, Reduce Downtime

The Alpha Laser ALFlak system is an indispensable tool for any facility involved in injection molding. Its advanced features, coupled with its robust construction, make it the ideal solution for:

• Repairing wear and tear
• Correcting design flaws
• Adding or modifying features
• Salvaging expensive mold components

By investing in an ALFlak, you’re not just buying a laser welder; you’re investing in increased uptime, reduced costs, and the peace of mind that comes with knowing your molds are always in peak condition.

Ready to transform your mold repair capabilities? Contact Alpha Laser today for a demo of the ALFlak and discover how precision laser welding can benefit your operations.

Summer’s here, and so is the heat! Is your Alpha Laser system ready?

Just like you wouldn’t want to run a marathon in a sauna, your laser doesn’t perform its best in extreme temperatures either. Overheating can lead to all sorts of headaches – from reduced performance to costly downtime. That’s where a Water Chiller comes in. Think of it as your laser’s personal air conditioner, a vital piece of equipment that keeps your system running smoothly by preventing it from getting too hot.

When is a Water Chiller a must-have for your laser welder?

• You’re Pushing Your System: Sometimes, project demands increase, and you might find yourself using your laser more than usual. All that extra work generates heat, and a chiller ensures your system can keep up without breaking a sweat.
• High-Power Jobs: Working with materials that need higher parameter settings? These operations naturally produce more heat. A chiller actively dissipates that extra warmth, letting you tackle intensive tasks confidently.
• No Perfect Climate Control? No Problem! Not every workspace is an ideal, climate-controlled environment. If your laser system is exposed to higher ambient temperatures, a Water Chiller provides the necessary internal cooling to counteract the external heat.

Fill out the form below to order!

In this episode, we showcase the laser welding repair of a mechanical hub used in the mining industry, revealing the power and flexibility of the AL FLAK 1200 fiber laser. See how casting defects are eliminated with precision and minimal heat input, preserving the integrity of the part and avoiding distortion or cracking.

Why laser over TIG/MIG?

• No need for preheating large components.
• Minimal thermal stress and reduced cooling requirements.
• Less porosity, no weld sink, and superior surface finish.
• Real-time visual control under magnification.

Using the ALPHA LASER system, we highlight:

• High-precision weld prep and repair on critical components.
• Efficient handling of large parts with minimal setup.
• Seamless correction of defects during welding.
• Laser welding advantages over traditional processes.

Learn how laser welding is transforming heavy industry repairs—saving time, money, and valuable parts.

In this episode, Jonathan and Mike showcase the repair of a plastic injection mold, blow mold and an extrusion die, demonstrating how laser welding restores worn and damaged components with pinpoint accuracy. Learn about the advantages of laser welding over traditional methods, including reduced heat input, minimal distortion, and the ability to weld dissimilar metals.

Using the AL-FLak fiber laser system, we highlight:

• Rapid setup and seamless job transitions
• High-precision welding of intricate mold details
• Effective repairs for parting edges, nozzle seats, and sidewalls
• The benefits of laser welding for mold longevity and efficiency

See how laser welding is revolutionizing the tool & die industry by extending the life of critical components and reducing downtime. Don’t miss this in-depth look at cutting-edge welding technology!

In this episode, Jonathan & Alex showcase the repair of a cast turbine blade made of René 80, a high-performance superalloy that is challenging to weld with conventional TIG or MIG methods. Using the AL Flak 1200 fiber laser, we achieve a precise and durable weld with C-263 filler material, ensuring the integrity of this expensive component.

Learn about the benefits of pulse mode welding, the importance of proper surface preparation, and why laser welding is a great solution for superalloy repairs—saving time, reducing costs, and extending the life of critical components.

Alpha Laser will be at the Plastics Technology Expo next month! Stop by to see live laser welding demos and try out welding for yourself at our booth.

When: March 18-20, 2025

Where: Rosemont, IL

Booth: 714

Promo code: 2502

Register

Join host Jonathan Filer in this episode of Alpha Welder as he showcases the AL-ROCK mobile laser system at Laser Hard, Inc. in Meadville, Pennsylvania. Discover how laser hardening offers a superior alternative to traditional induction hardening, eliminating part deformation and ensuring precise, localized hardening.

Learn how this innovative process reduces heat input, maintains material integrity, and eliminates the need for post-processing. With real-time temperature monitoring and pre-programmed processes, laser hardening revolutionizes durability and efficiency for heat-sensitive components. Watch now to see cutting-edge laser technology in action!

Want to see the AL-ROCK in person? Request a demo: 

Join Jonathan Filer from ALPHA LASER US in Meadville, Pennsylvania, at Phoenix Laser Solutions as he showcases the AL-Flak 1200 fiber laser in action. In this episode, we demonstrate the repair of an Inconel 738 vane ring for the turbo machinery industry, using Inconel 625 filler material.

Discover the advantages of continuous wave (CW) laser welding, innovative tools like the ergo wedge, and how this technology enables precision repairs without pre or post weld heat treatment.

Want to see the AL-FLAK in person? Request a demo: