Micro Welding Course

Lesson 1 • Common Micro Welding Processes

Surveys laser, resistance, electron beam, and micro TIG processes. Provides a framework for selecting the right process in later chapters.

Lesson 2 • Materials Behavior at Micro Scale

Covers how metals, alloys, and thin films respond to micro-scale heat input. Prepares students to anticipate distortion and metallurgical challenges.

Lesson 3 • Physics of Micro-Scale Fusion

Explains heat generation, thermal gradients, and surface tension at micro scale. Connects physics principles to practical weld quality outcomes.

Lesson 4 • Safety and Regulatory Fundamentals

Establishes laser radiation, electrical, and fume hazards specific to micro welding. Ensures compliance with workplace safety standards before hands-on work begins.

Lesson 1 • Resistance and Micro TIG Equipment

Covers resistance welding heads, electrode holders, and micro TIG torch assemblies. Builds equipment literacy needed for process-specific chapters.

Lesson 2 • Workspace Calibration and Maintenance

Covers beam alignment, electrode conditioning, and preventive maintenance schedules. Ensures equipment performs within specification before every production run.

Lesson 3 • Fixturing and Workholding Devices

Introduces precision vises, vacuum chucks, and custom fixtures for micro-scale parts. Proper fixturing prevents movement that causes weld defects.

Lesson 4 • Microscopy and Vision Systems

Explains stereo microscopes, CCD cameras, and coaxial viewing systems used during welding. Develops the visual acuity skills essential for precision work.

Lesson 1 • Shielding Gas Fundamentals

Explains the role of argon, helium, and mixed gases in protecting micro weld pools. Gas choice directly affects arc stability and weld appearance.

Lesson 2 • Pre-Weld Inspection Techniques

Introduces visual, dimensional, and surface roughness checks before welding begins. Early defect detection prevents scrap and rework downstream.

Lesson 3 • Surface Cleaning and Preparation

Teaches chemical cleaning, mechanical abrasion, and ultrasonic methods for micro parts. Clean surfaces are the single greatest factor in micro weld quality.

Lesson 4 • Gas Delivery System Design

Covers micro nozzle design, trailing shields, and purge chambers for sensitive alloys. Proper delivery prevents turbulence that introduces porosity.

Lesson 1 • Troubleshooting Laser Weld Defects

Identifies porosity, undercut, spatter, and incomplete fusion causes and corrections. Links defect appearance to specific parameter adjustments.

Lesson 2 • Laser Parameter Fundamentals

Defines peak power, average power, pulse energy, and duty cycle for pulsed lasers. These variables govern heat input and weld geometry.

Lesson 3 • Parameter Development and Testing

Guides students through coupon testing, bead-on-plate trials, and parameter matrices. Systematic testing produces validated parameter sets for production.

Lesson 4 • Focus Position and Beam Delivery

Explains focal length, depth of focus, and defocus strategies for penetration control. Beam positioning errors are a leading cause of incomplete fusion.

Lesson 1 • Filler Wire Addition at Micro Scale

Covers micro filler wire diameters, feed angles, and manual dip technique for micro TIG. Filler addition must not disturb the arc or contaminate the tungsten.

Lesson 2 • Resistance Welding Process Control

Covers weld current, time, electrode force, and hold time as the four primary variables. Balancing these variables produces consistent nugget size and strength.

Lesson 3 • Electrode Selection and Management

Explains electrode alloy grades, tip geometry, and wear mechanisms for micro resistance welding. Electrode condition is the most common cause of weld variation.

Lesson 4 • Welding Dissimilar Metal Combinations

Addresses intermetallic formation, dilution control, and filler selection for dissimilar pairs. Dissimilar welds require modified parameters from same-metal baselines.

Lesson 1 • Defect Classification and Disposition

Teaches systematic defect classification, root cause identification, and repair or reject decisions. Consistent disposition prevents nonconforming parts from reaching assembly.

Lesson 2 • Mechanical Testing of Micro Welds

Applies micro tensile, peel, shear, and hardness tests to quantify weld strength. Mechanical data validates that welds meet design load requirements.

Lesson 3 • Non-Destructive Evaluation Methods

Introduces dye penetrant, X-ray, and ultrasonic testing adapted for micro weld scale. NDE preserves parts while detecting subsurface discontinuities.

Lesson 4 • Metallographic Cross-Section Analysis

Covers sectioning, mounting, polishing, and etching micro weld samples for microscopic examination. Cross-sections reveal internal defects invisible from the surface.

Lesson 1 • In-Process Monitoring Technologies

Covers photodiode, pyrometer, and plasma emission monitoring for real-time weld feedback. Inline monitoring catches drift before defective parts accumulate.

Lesson 2 • Gauge and Equipment Calibration Control

Covers calibration intervals, traceability to measurement standards, and out-of-calibration response. Calibrated equipment is the foundation of reliable process data.

Lesson 3 • Weld Parameter Documentation Systems

Establishes weld procedure specifications, traveler cards, and digital parameter logging. Traceability links every weld to its recorded process conditions.

Lesson 4 • Continuous Improvement in Micro Welding

Applies PDCA cycles, fishbone analysis, and design of experiments to reduce weld variation. Structured improvement methods sustain gains beyond initial qualification.

Lesson 1 • Medical Device Micro Welding

Addresses biocompatible alloy selection, cleanliness standards, and traceability for implantable devices. Medical welding demands zero-defect outcomes and full process documentation.

Lesson 2 • Electronics and Microelectronics Welding

Covers battery tab welding, wire bonding alternatives, and PCB component attachment. Thermal sensitivity of electronics demands precise energy control.

Lesson 3 • Aerospace and Defense Applications

Applies micro welding to turbine blade repair, fuel system components, and sensor housings. Aerospace specifications require certified procedures and first-article inspection.

Lesson 4 • Mold and Tool Repair Welding

Uses micro laser welding to restore worn or damaged mold cavities and cutting tools. Repair welding extends tool life and reduces replacement costs significantly.