Weld Bead Geometry Calculator
Predict weld bead dimensions from welding parameters.
Optimal Bead Geometry Ratios
| Parameter | Ideal Range | Notes |
|---|---|---|
| Width/Depth Ratio | 1.5 - 2.5 | Prevents centerline cracking |
| Reinforcement | 1-3 mm | Excessive = stress riser |
| Penetration/Thickness | 15-25% | For fillet welds |
| Contact Angle | 45-60 deg | Good toe blend |
Understanding Weld Bead Geometry
Key Geometric Parameters
- Bead Width (W): Distance across the weld face - affected mainly by voltage and travel speed
- Bead Height (H): Reinforcement above base metal - wire feed vs travel speed
- Penetration (P): Depth into base metal - primarily current dependent
- Dilution: Percentage of base metal in weld - increases with current
Parameter Effects
- Increase Current: More penetration, slightly wider bead
- Increase Voltage: Wider, flatter bead, less penetration
- Increase Travel Speed: Narrower, lower reinforcement, less penetration
- Increase Wire Speed: More reinforcement, slight penetration increase
Quality Considerations
- Too Narrow: W/D ratio < 1.0 risks centerline solidification cracking
- Too Wide: Poor penetration, cold lap at toes
- Excessive Height: Creates stress concentration, wastes material
- Concave Profile: May indicate insufficient filler or high heat