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Quick Answer: Welding Mode Thresholds
Conduction: <2000 W/mm² | Transition: 2-8 kW/mm² | Keyhole: >8 kW/mm² → deep penetration
Estimate laser weld penetration depth based on power, speed, and spot size. Determines keyhole vs conduction mode and provides quality recommendations.
Enter welding parameters to estimate penetration depth.
Weld depth estimate
Send the material, power, speed, spot size, and penetration-depth result before changing weld parameters.
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| Power | 1 m/min | 2 m/min | 5 m/min | Mode |
|---|---|---|---|---|
| 2 kW | 3-4 mm | 2-3 mm | 1-1.5 mm | Keyhole |
| 4 kW | 5-7 mm | 4-5 mm | 2-3 mm | Keyhole |
| 6 kW | 7-10 mm | 5-7 mm | 3-4 mm | Keyhole |
| 12 kW | 12-16 mm | 8-12 mm | 5-7 mm | Deep Keyhole |
Values for mild/carbon steel with 0.3mm spot, nitrogen shielding. Stainless: similar. Aluminum: 10-20% less due to high conductivity.
Conduction mode: Power density <2000 W/mm². Wide, shallow weld pool. Heat transfers via conduction. Low aspect ratio (depth:width ≈ 0.5). Good for thin materials, cosmetic welds. Keyhole mode: Power density >8000 W/mm². Creates vapor cavity (keyhole) that allows deep beam penetration. High aspect ratio (depth:width >1). Required for deep penetration and thick materials. Transition mode is between these two.
Calculate W/mm² to determine weld mode
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M² determines achievable spot size
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Note: Penetration estimates are based on empirical models and typical conditions. Actual penetration varies with material composition, joint configuration, shielding gas, and beam quality. Always validate with test welds and cross-section examination per AWS D17.1 or your applicable standard.
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