Weld Profile Estimator
Estimate weld cross-section geometry including penetration depth, bead width, and HAZ dimensions. Treat the profile view as a planning aid before test weld validation.
Welding Parameters
Negative = below surface (deeper), Positive = above surface (wider)
Material Properties
Enter parameters to estimate weld profile
Understanding Weld Profile
Weld Cross-Section Profiles
Conduction vs Keyhole Mode penetration patterns
Transition band: Power density around 10⁵-10⁶ W/cm² can show mixed-mode behavior. Treat the thresholds as screening bands and validate with cross-sections.
Aspect Ratio (D/W) Screening Bands
- 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 - deeper penetration tendency
- D/W > 1.5: Deep keyhole - high aspect-ratio, narrow bead tendency
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 formation can allow deeper penetration. It usually needs high power density and is common in thicker-section or butt-joint development work.
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)
How to Apply This Estimate
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
Validate with test welds. Start here, then adjust based on actual cross-sections, inspection criteria, and the responsible welding procedure.