Weld Bead Width Calculation
Use this weld width calculator to estimate bead width from laser power, travel speed, focus spot size, material heat spreading, beam shape, and wobble amplitude. The result is a planning estimate for trial welds, not an acceptance limit for a production drawing.
What changes weld bead width?
- Focus spot diameter: Larger spots normally produce wider beads.
- Heat input: Higher power or lower speed generally increases molten-pool size.
- Material: Aluminum and copper spread heat more than stainless steel or titanium.
- Wobble amplitude: Oscillation adds lateral motion and can widen the effective bead.
- Beam shape: Circular, square, ring, and line beams distribute energy differently.
Understanding Weld Bead Geometry
Weld bead geometry (width, depth, shape) affects joint strength, appearance, and process stability. Proper control supports repeatable trials and makes inspection results easier to compare.
Aspect Ratio Significance
- High Aspect Ratio (> 1.5): Deep, narrow welds. Good penetration, keyhole mode, may have porosity risk
- Balanced (1.0-1.5): General-purpose planning range; confirm stability with trial welds
- Low Aspect Ratio (< 1.0): Wide, shallow welds. Good for thin materials and surface sealing
Controlling Weld Width
- Focus Spot Size: Smaller spot = narrower weld
- Power Density: Higher density creates keyhole mode (narrow weld)
- Welding Speed: Faster speed reduces width but may sacrifice depth
- Defocus: Moving focus above/below surface increases width
Material Effects
High thermal conductivity materials (aluminum, copper) produce wider welds due to heat spreading. Low conductivity materials (stainless steel, titanium) concentrate heat for narrower welds.