Weld Profile Predictor
Predict weld cross-section geometry including penetration depth, bead width, and HAZ dimensions. Visualize the weld profile before welding.
Welding Parameters
Negative = below surface (deeper), Positive = above surface (wider)
Material Properties
Enter parameters to predict weld profile
Understanding Weld Profile
Weld Cross-Section Profiles
Conduction vs Keyhole Mode penetration patterns
⚠️ Transition Zone: Power 10⁵-10⁶ W/cm² creates unstable mixed mode. Target clear conduction (<10⁵) or keyhole (>10⁶) for consistent results.
Aspect Ratio (D/W)
- D/W < 0.5: Conduction mode - wide, shallow weld
- D/W 0.5-1.0: Transition mode
- D/W 1.0-1.5: Keyhole mode - good penetration
- D/W > 1.5: Deep keyhole - high penetration, narrow bead
Weld Modes
Conduction Mode: Heat conducted from surface. Produces wide, shallow welds. Lower power density, suitable for thin materials and cosmetic welds.
Keyhole Mode: Vapor cavity forms, allowing deep penetration. High power density required. Typical for thick sections and butt joints.
Key Dimensions
- Penetration: Depth of fusion into base material
- Width: Top surface width of fusion zone
- Reinforcement: Crown height above surface
- HAZ: Heat-affected zone (not melted but microstructure changed)
Prediction Accuracy
This calculator provides estimates based on simplified heat transfer models. Actual results depend on many factors:
- Beam quality (M² value)
- Joint fit-up and gap
- Shielding gas type and flow
- Material surface condition
- Cooling rate and fixturing
Always verify with test welds! Use this as a starting point, then adjust based on actual cross-sections.