Input Parameters
Calculation Results
Enter parameters and click Calculate to see results
Material Starting Bands
| Material | Thickness | Power | Speed | Gas Flow | Penetration |
|---|---|---|---|---|---|
| 304 Stainless Steel | 1.0 mm | 1.2-1.5 kW | 60-80 mm/s | 12 L/min (Ar) | 0.8-1.0 mm |
| 304 Stainless Steel | 2.0 mm | 1.8-2.2 kW | 40-60 mm/s | 14 L/min (Ar) | 1.8-2.0 mm |
| 6061 Aluminum | 1.0 mm | 2.3-2.8 kW | 45-55 mm/s | 15 L/min (Ar) | 0.9-1.1 mm |
| Carbon Steel Q235 | 2.0 mm | 1.5-1.9 kW | 55-70 mm/s | 12 L/min (CO₂/Ar) | 1.9-2.1 mm |
| Titanium TA2 | 1.5 mm | 2.0-2.5 kW | 35-45 mm/s | 18 L/min (Ar HP) | 1.4-1.6 mm |
Note: Parameters shown are for butt welding. Adjust -15% power for lap joints, +20% for fillet welds. HP = High Purity Argon (99.99%+).
Parameter Decisions
What starting range can be used for welding 2mm stainless steel?
For 2mm 304 stainless steel butt-weld planning, a first-pass range around 1.8-2.2 kW and 40-60 mm/s can be trialed. Actual release settings depend on joint configuration, optics, fit-up, shielding, and inspection results. Lap joints may need a different range because heat confinement and interface contact change the weld pool.
Why does aluminum require higher laser power than steel?
Aluminum reflects more energy than steel at common fiber-laser wavelengths and dissipates heat rapidly. In practice that usually means a narrower parameter window and a higher delivered-energy requirement than a comparable steel joint, which is why trial welds and cross-sections matter.
How do I choose between single-pass and multi-pass welding?
Single-pass welding may be suitable for thinner sections where heat input control is critical and penetration can be confirmed in one pass. Multi-pass welding is often used for thicker sections to manage penetration, heat input, and stress. The final choice should be confirmed with cross-sections and inspection.
What shielding gas should I use for different materials?
Argon (Ar): Common starting point for stainless steel, aluminum, and titanium trials. Titanium work often needs high-purity shielding and trailing protection.
CO₂/Ar Mix: Common carbon-steel shielding option when the process allows mixed shielding.
Helium (He): Consider for high-conductivity materials like copper, or as part of an argon blend when additional heat transfer or plume control is needed.
How should these calculated parameters be used?
The calculated parameters are planning estimates. Actual release settings vary with alloy condition, surface state, joint fit-up, shielding coverage, optics, and machine behavior. Always validate with test welds, cross-sections, and inspection.
What is the relationship between power, speed, and heat input?
Heat input (J/mm) = Power (W) / Speed (mm/s). Maintaining constant heat input while adjusting power and speed proportionally can help compare process windows. However, excessively high power with high speed may cause instability, while low power with low speed increases HAZ size. The calculator helps compare tradeoffs before trial welds.
Can I use the same parameters for different thicknesses of the same material?
No. Thickness changes the heat balance and penetration demand, so the parameter window should be recalculated and revalidated whenever section size changes. Use the output as a starting range and confirm it with trial welds.
How do I choose parameters for dissimilar metal welding?
For dissimilar metals, start the parameter window around the material with higher thermal conductivity or reflectivity, then evaluate beam offset, filler compatibility, intermetallic risk, and inspection requirements. Trial welds and metallurgical examination are essential for dissimilar metal joints.
Process Stability Checks
1Surface Preparation
Clean surfaces thoroughly to remove oils, oxides, and contaminants. For aluminum, remove the oxide layer immediately before welding. Good surface preparation usually makes the parameter window easier to stabilize and inspect.
2Joint Fit-Up
Maintain tight joint gaps (<10% of thickness). Poor fit-up requires higher power and slower speed, increasing heat input and distortion risk. Use fixturing to ensure consistent gap.
3Focus Position
For most applications, focus slightly below the surface (-0.5 to -2mm from surface). Deeper focus increases penetration but may reduce weld width. Adjust based on thickness and desired weld profile.
4Process Monitoring
Monitor weld pool stability, spatter, and penetration. Excessive spatter indicates too much power or contamination. If penetration is low, adjust one variable at a time and confirm the result with sectioning or other inspection.