Laser Welding Power Calculator
Calculate laser welding parameters for keyhole and conduction mode welding.
Power Density Thresholds
| Mode | Power Density | Characteristics |
|---|---|---|
| Conduction | 10^4 - 10^5 W/cm2 | Wide, shallow |
| Transition | 10^5 - 10^6 W/cm2 | Mixed mode |
| Keyhole | > 10^6 W/cm2 | Deep, narrow |
Laser Welding Fundamentals
Power Density Formula
Power Density (W/cm2) = Laser Power / Spot Area. For keyhole welding, typically > 10^6 W/cm2 is required.
Keyhole vs Conduction Mode
- Keyhole: High power density vaporizes metal creating a vapor cavity. Deep penetration (aspect ratio > 1), narrow HAZ.
- Conduction: Heat transfer by conduction only. Wide, shallow weld pool. Better for thin materials and cosmetic welds.
- Hybrid: Laser + arc source. Combines deep penetration with gap bridging capability.
Material Considerations
- Reflective Materials: Copper, aluminum require higher power for initiation (use fiber/disc lasers)
- Shielding: Argon or helium to protect weld pool and optics from spatter
- Focus Position: Typically 0 to -1mm below surface for keyhole mode
- Gap Tolerance: < 0.1mm for autogenous, use filler wire for larger gaps