Laser Welding Thickness Chart & Power Settings

Laser welding process parameter setting

The key to laser welding equipment is the setting and adjustment of process parameters. Different scanning speeds, widths, powers, etc., are selected according to the material thickness and type (duty cycle and pulse frequency usually do not need to be adjusted). Common process parameters are shown in the table below.

Laser welding linear process parameters

① Optimize the galvanometer’s oscillation amplitude to precisely match the width of the workpiece being welded. This ensures uniform energy distribution across the weld seam.

② Laser power requirements correlate directly with material thickness. Thicker plates demand higher laser power to achieve full penetration, while thinner materials require less power to prevent burn-through and distortion.

③ For thin plates below 1.0mm, fine-tuning of laser parameters is crucial. Adjust the duty cycle based on material thickness to control heat input and penetration depth. These parameters primarily influence the weld penetration characteristics and minimize the heat-affected zone (HAZ).

④ The linear welding technique is versatile, suitable for various joint configurations including diagonal and butt welds. It offers consistent weld quality across different geometries when properly optimized.

⑤ The optimal frequency range for the welding head oscillation is 4-20Hz. Within this range, adjust the power density according to material properties, thickness, and desired weld characteristics. Higher frequencies generally allow for faster welding speeds but may require increased power.

⑥ For internal angle welding, employ a narrow galvanometer oscillation width. Reducing the oscillation amplitude concentrates the energy, resulting in deeper penetration and stronger fusion at the joint interface. However, balance this with the risk of undercutting or excessive penetration.

Special note:

The aforementioned parameters serve as general guidelines and should be fine-tuned based on several critical factors, including laser power output, material composition and properties, specific welding technique, and joint width. As a rule of thumb, thinner plates require lower laser power, while thicker plates demand higher power settings. However, this relationship is not strictly linear and may vary depending on the material’s thermal conductivity and reflectivity.

The laser head control parameters also play a crucial role in achieving optimal weld quality. The linetype parameter is particularly effective for diagonal welds and male fillet joints, as it allows for precise energy distribution along the weld path. In contrast, the O-type parameter offers versatility and is well-suited for a wide range of welding applications, including butt joints, lap joints, and complex geometries.

It’s important to note that these parameters should be validated through practical trials and may require iterative adjustments to achieve the desired weld characteristics, such as penetration depth, bead width, and minimal heat-affected zone. Additionally, factors like shielding gas composition, flow rate, and nozzle design can significantly influence the welding process and should be considered in conjunction with the laser parameters.

For optimal results, it is recommended to develop a comprehensive welding procedure specification (WPS) that takes into account all relevant variables and is tailored to the specific material and joint configuration being welded.

Laser welding O-type process parameters

① Adjust the galvanometer’s oscillation amplitude to precisely match the width of the workpiece being welded. This ensures optimal energy distribution across the weld seam.

② The required laser power correlates directly with the plate thickness. Thicker plates demand higher laser power to achieve full penetration, while thinner plates require less power to prevent overheating or burn-through.

③ For thin plates below 1.0mm, fine-tuning of parameters is crucial. Adjust focal point position, pulse duration, and energy density to control penetration depth and minimize heat-affected zone (HAZ). These parameters primarily influence the weld penetration and mechanical properties of the thin plate joint.

④ The linear welding pattern is versatile, suitable for various joint configurations including diagonal and butt welds. However, consider beam shaping techniques for optimizing energy distribution in specific joint geometries.

⑤ The welding gun’s frequency range of 4-20Hz allows for process optimization. Lower frequencies typically suit thicker materials, while higher frequencies are beneficial for thin plates. Adjust power density in conjunction with frequency to achieve the desired weld characteristics.

⑥ The O-type welding mode, utilizing double motor oscillation, is adaptable to diverse welding applications. This technique ensures thorough material melting and promotes uniform mixing in the weld pool, resulting in superior weld stability compared to linear welding. The enhanced energy input necessitates higher laser power, but offers benefits such as improved gap bridging ability and reduced porosity in the weld seam.

Special note:

The parameters provided serve as general guidelines and should be fine-tuned based on specific factors including laser power, material properties, welding technique, and joint width. As a rule of thumb, thinner plates require lower laser power, while thicker plates demand higher power settings. Regarding laser head control, the linetype parameter is particularly effective for diagonal and male fillet welds, whereas the O-type parameter is versatile and suitable for a wide range of welding applications.

It’s crucial to consider the following when optimizing laser welding parameters:

1. Material characteristics: Thermal conductivity, reflectivity, and melting point of the workpiece significantly influence parameter selection.
2. Joint geometry: Different joint configurations (butt, lap, fillet) may require distinct parameter adjustments for optimal results.
3. Welding speed: This parameter directly affects heat input and weld penetration, requiring careful balance with laser power.
4. Focal position: Adjusting the focal point relative to the workpiece surface can optimize energy distribution and weld profile.
5. Shielding gas: The type and flow rate of shielding gas impact weld quality and should be tailored to the specific application.
6. Pulse shaping: For pulsed laser welding, manipulating pulse duration and frequency can enhance weld characteristics and minimize defects.

Always conduct test welds on representative samples to validate and refine parameter settings before commencing production welding. This approach ensures consistent weld quality, minimizes defects, and optimizes process efficiency in industrial applications.