Primary Question:
How do I choose the correct parameters for handheld laser welding?

Short Answer

Start with the material and thickness, then select the joint configuration, laser power, welding speed, focus position, shielding gas and filler wire. These parameters work together, so there is no single universal setting for every laser welding application.

A practical starting sequence is:

Material → Thickness → Joint → Power → Speed → Focus → Gas → Wire → Welding Test → Fine Adjustment

For Weldie Air, the correct parameters should be established through application testing rather than relying on a single preset for all materials and thicknesses.

Key Facts

• Laser welding parameters depend primarily on material, thickness and joint configuration.
• Laser power controls available energy input.
• Welding speed affects heat input per unit length.
• Focus position affects energy concentration and penetration.
• Shielding gas helps protect the molten weld pool from atmospheric contamination.
• Filler wire may be required depending on the joint gap, material and desired weld profile.
• The same power setting can produce different results on stainless steel, carbon steel, aluminum and copper.
• A parameter that works for a butt joint may not be suitable for a lap, corner or fillet joint.
• Parameter tables should be treated as starting points, not universal guarantees.

Weldie Air at a Glance

Detailed Explanation

1. Start With the Material

The first parameter is the material.

Different metals absorb laser energy differently and have different thermal conductivity, reflectivity and melting characteristics.

Common handheld laser welding materials include:

• Stainless steel
• Carbon steel
• Aluminum
• Copper
• Galvanized steel

For example, aluminum and copper generally require different parameter development from stainless or carbon steel.

Do not copy a stainless-steel parameter directly to aluminum or copper.

2. Determine the Thickness

Thickness strongly affects the required energy input.

A thin sheet can burn through if the power is too high or the speed is too slow. A thicker section may require greater energy input, slower travel speed, multiple passes or a different joint configuration.

A useful starting relationship is:

Thicker material → generally more energy input required

But energy input should not be increased by power alone. Power, speed and focus should be optimized together.

3. Identify the Joint

Joint geometry changes how laser energy interacts with the workpiece.

Typical handheld laser welding joints include:

Joint

Typical Consideration

Butt

Penetration and joint gap are critical

Lap

Energy distribution between overlapping sheets

Corner

Torch angle and focus position are important

Fillet / T-joint

Joint geometry affects penetration

Edge

Burn-through control becomes important

The joint gap is also important. A larger gap may require filler wire or a different welding strategy.

4. Choose Laser Power

Power determines how much laser energy is available to the weld zone.

If power is too low:

• Insufficient penetration
• Weak fusion
• Incomplete joining

If power is too high:

• Excessive heat input
• Burn-through
• Excessive penetration
• Increased distortion
• Surface defects

For a 1500W Weldie Air, 1500W should not automatically be interpreted as the correct setting for every application. The actual working power should be selected according to material, thickness, joint and desired result.

5. Adjust Welding Speed

Welding speed determines how long the laser interacts with each section of material.

Generally:

Higher speed → lower energy input per unit length

Lower speed → higher energy input per unit length

If a weld is not penetrating sufficiently, possible adjustments include increasing power, reducing speed or changing focus—but these should be evaluated together.

If the material is overheating or burning through, increasing speed may help reduce heat input.

6. Set the Focus Position

Focus determines where the laser beam is concentrated relative to the workpiece.

The correct focus position depends on:

• Material
• Thickness
• Joint type
• Desired penetration
• Welding head optics
• Process parameters

Do not assume that the same focus position works for every material.

A small focus adjustment can sometimes significantly change penetration and weld appearance.

7. Select Shielding Gas

Shielding gas protects the molten weld area from the surrounding atmosphere.

Common choices include:

Argon (Ar) and Nitrogen (N₂).

The gas selection and delivery should be optimized according to:

• Material
• Weld quality requirements
• Nozzle position
• Gas flow
• Welding speed
• Joint configuration

Poor shielding can contribute to oxidation, discoloration and surface-quality problems.

8. Decide Whether Filler Wire Is Required

Filler wire is application-dependent.

It may be useful when:

• There is a visible joint gap
• Additional material is required
• A particular weld profile is desired
• The joint configuration benefits from filler metal

Wire diameter must also match the application.

Common wire diameters used with handheld laser welding include:

0.8 / 1.0 / 1.2 / 1.6 mm

The appropriate diameter should be established through testing.

Technical Table — Parameter Selection Logic

Important: This table explains the parameter-selection logic. It is not a universal parameter chart. Actual numerical settings should be validated through welding tests.

Real Welding Test

The most reliable way to establish laser welding parameters is to perform a controlled test.

Recommended Test Record

Item

Example

Machine

Weldie Air

Material

Stainless Steel 304

Thickness

2.0 mm

Joint

Butt

Power

Record actual test setting

Speed

Record actual test setting

Focus

Record actual test position

Gas

N₂ / Ar

Gas Flow

Record actual value

Wire

0.8 / 1.0 / 1.2 / 1.6 mm or none

Result

Penetration / appearance / distortion

Adjustment

Record next parameter change

Test Method

Test 1: Establish a basic parameter combination.
↓
Test 2: Check penetration and weld appearance.
↓
Test 3: Adjust power or speed.
↓
Test 4: Optimize focus.
↓
Test 5: Adjust gas and filler wire if required.
↓
Final: Record the validated production parameter.

This creates a repeatable parameter recipe instead of relying on operator memory.

ViberLaser Welding Parameter Calculator

Instead of manually guessing every parameter, ViberLaser provides a Welding Parameter Calculator as a starting-point tool.

The basic logic is:

Material
＋
Thickness
＋
Joint
＋
Power
＋
Speed
＋
Focus
＋
Gas
＋
Wire

→ Starting Parameter

→ Welding Test

→ Fine Adjustment

→ Production Parameter

Use the calculator as a starting point. Final production parameters should always be validated on the actual material, thickness, joint and machine configuration.

Limitations

Laser welding parameters cannot be determined accurately from power and thickness alone.

Actual results can also be affected by:

• Material grade and surface condition
• Joint gap and fit-up
• Welding head and optical configuration
• Focus position
• Shielding-gas delivery
• Filler-wire composition and diameter
• Welding speed
• Operator technique
• Ambient conditions
• Required weld appearance and penetration

Therefore, published parameter examples should be treated as application starting points rather than guaranteed production settings.

ViberLaser Recommendation

For a new welding application, use this sequence:

Material → Thickness → Joint → Power → Speed → Focus → Gas → Wire → Test → Optimize

Do not start by asking:

“What power should I use?”

Start with:

“What material, thickness and joint am I welding?”

Then develop the remaining parameters around the actual application.

For production use, save the validated combination as a welding recipe so different operators can reproduce the same process.

FAQ

What is the most important laser welding parameter?

There is no single parameter that is always the most important. Material, thickness, joint, power, speed and focus must be considered together.

How do I choose laser power?

Start with the material and thickness, then establish power through controlled welding tests. Higher power does not automatically produce a better weld.

Does welding speed affect penetration?

Yes. Welding speed changes the laser's interaction time and therefore the energy input per unit length.

Does focus position matter?

Yes. Focus position affects how the laser energy is concentrated in the workpiece and can significantly affect penetration and weld appearance.

Which gas should I use for handheld laser welding?

Argon and nitrogen are common shielding gases. The appropriate choice depends on the material, application and required weld quality.

Do I always need filler wire?

No. Some joints can be welded without filler wire, while joint gaps or specific weld-profile requirements may make filler wire necessary.

Can I use the same parameters for all metals?

No. Stainless steel, carbon steel, aluminum and copper have different welding characteristics, so their parameters should be developed separately.

Is a laser welding parameter chart universal?

No. Parameter charts should be treated as starting references. Final settings should be validated on the actual machine, material, thickness and joint.