⚡ 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.
| 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.
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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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