From estimate to test weld
Laser Welding Parameter Window Guide
How to convert calculator output into a bounded test matrix for power, speed, focus, and gas.
Starting point3 x 3 matrix
Start with power, speed, and focus as the first controlled variables.
Hold constantGas + fixture
Do not change shielding, fit-up, or clamping while reading the first samples.
OutputNarrowed window
Keep the settings that meet penetration, bead shape, and defect targets.
Build the first test matrix
Start with one material, one thickness, one joint design, and one optics setup. Change only the variables listed below until the first sample set is measured.
| Variable | How to set the first range | What to record |
|---|---|---|
| Laser power | Choose a low, middle, and high value around the calculator output. | Record lack of fusion, excessive penetration, spatter, and HAZ width. |
| Travel speed | Pair each power value with slow, middle, and fast travel speeds. | Record bead width, undercut, porosity, and cycle-time impact. |
| Focus position | Hold focus fixed for the first pass; then test one negative and one positive offset. | Record penetration depth, keyhole stability, and top-bead shape. |
| Shielding gas | Lock gas type, flow, nozzle distance, and angle before comparing samples. | Record oxidation, soot, porosity, and plume behavior. |
Narrow the process window
| Signal | Keep the setting when | Change the setting when |
|---|---|---|
| Penetration | Cross-section depth matches the joint target without excessive root melt. | Depth is below target, root melt is excessive, or penetration varies across samples. |
| Surface quality | Bead width, spatter, undercut, and porosity stay inside the project target. | Visible defects increase as power or speed changes. |
| Thermal control | Distortion, HAZ width, and fixture temperature remain manageable. | Part movement, excessive HAZ, or fixture heat-up appears. |
Next engineering checks
Energy & Heat CalculatorEstimate laser power, travel speed, heat input, and thermal load before process trials.Multi-Variable AnalyzerCompare power, speed, focus, gas, and material interactions for early parameter selection.Process Parameters CalculatorGenerate a first-pass parameter card for common laser welding setups.Material Process Window TableStarting assumptions for common materials, thickness ranges, shielding gases, and process cautions.Precision Seam WeldingA process loop for thin sheet, enclosure, and precision seam weld parameter control.