Core Laser Welding Parameters (Explained)
Video: Handheld Laser Welding Parameters
Watch a quick walkthrough of how peak power, wobble, wire feed, gas flow and focus position affect weld quality.
Peak Power (%)
Peak power controls penetration depth and the size of the molten pool. On the M-Series 1200 W handheld system, typical peak power settings for thin sheet are:
- Stainless steel 0.5–1.0 mm: 23–38 %
- Stainless steel 1.2–1.5 mm: 40–45 %
- Stainless steel 2.0–3.0 mm: 45–65 %
- Carbon steel 2.0–4.0 mm: 67–95 %
- Aluminium 1.0–2.0 mm: 50–85 %
Higher peak power increases penetration but also raises heat input. For thin visible parts, it is usually better to start at the lower end of the window and increase gradually until full fusion is reached.
Wire Diameter and Feed Rate
For joint gap and cosmetic seams, see the full wire-feed laser welding guide.
Wire is used to fill gaps, increase bead width and improve joint strength. From our welding table:- 0.8 mm stainless uses 0.8 mm wire at 18 mm/s (30 % peak power).
- 1.5 mm stainless uses 1.2 mm wire at 13 mm/s (40 % peak power).
- 3.0 mm stainless uses 1.2 mm wire at 8 mm/s (65 % peak power).
- 3.0–4.0 mm carbon steel uses 1.6 mm wire at 6–8 mm/s (85–95 % peak power).
- 2.0 mm aluminium uses 1.6 mm wire at 10 mm/s (85 % peak power).
As a rule of thumb, thicker plates require larger wire diameters and lower feed rates to maintain a stable pool.
Wobble Scan Width (mm)
Wobble scan width defines the lateral movement of the beam and directly affects bead width and heat distribution. The M-Series test data uses:
- Thin sheet (0.5–1.0 mm): 1.5–2.5 mm scan width
- 1.2–2.0 mm sheet: 3.0–3.5 mm scan width
- 3.0–4.0 mm sheet: 4.0–4.5 mm scan width
Increasing scan width helps avoid burn-through on very thin materials and improves tolerance to joint fit-up variations.
Wobble Frequency (Hz)
Wobble frequency (scanning frequency) influences bead smoothness and agitation of the molten pool:
- 0.5 mm stainless: up to 150 Hz for very smooth beads.
- 0.8–1.5 mm stainless and carbon steel: typically 60–100 Hz.
- 2.0–4.0 mm sheet: 25–40 Hz to keep energy concentrated.
Shielding Gas and Flow Rate
Gas choice and flow stability strongly affect porosity/oxidation — read does laser welding require gas?
All tests use nitrogen shielding with a flow of ≥20 L/min. If the flow is too low, oxidation and porosity will increase. Excessively high flow may disturb the molten pool. For aluminium and stainless steel, maintaining a stable, laminar gas flow is critical for bright, clean welds.Focus Position
Focus position changes how the beam energy is distributed along the thickness:
- Stainless and carbon steel: focus at the surface (0 mm) for most butt and fillet welds.
- Aluminium: focus shifted +3 to +5 mm above the surface to reduce soot and porosity.
Correct focus is especially important when welding reflective materials or when you want to minimise top-side spatter.
Recommended Parameter Windows (1200 W)
The following tables summarise representative 1200 W handheld welding parameters for thin sheet. Values are indicative starting points and should be fine-tuned for each material batch and joint design.
Go deeper by material
Stainless Steel (0.5–4.0 mm)
| Thickness (mm) | Wire Ø (mm) | Wire Feed (mm/s) | Peak Power (%) | Scan Width (mm) | Frequency (Hz) | Typical Use |
|---|---|---|---|---|---|---|
| 0.5 | — | — | 23 | 1.5 | 150 | Micro lap welds, thin covers |
| 0.8 | 0.8 | 18 | 30 | 2.5 | 100 | General thin sheet, visible seams |
| 1.0 | 0.8 | 18 | 38 | 2.5 | 100 | Cabinet panels, brackets |
| 1.2 | 1.0 | 15 | 40 | 3.0 | 100 | Frame and enclosure welding |
| 1.5 | 1.2 | 13 | 40 | 3.0 | 60 | Corner joints on boxes and doors |
| 2.0 | 1.2 | 12 | 45 | 3.5 | 40 | Reinforced brackets, stiffeners |
| 2.5 | 1.2 | 10 | 50 | 3.5 | 40 | Heavier frames and posts |
| 3.0 | 1.2 | 8 | 65 | 4.5 | 30 | Load-bearing joints on 3 mm sheet |
| 4.0 | 1.2 | 6 | 75 | 4.5 | 25 | Near maximum thickness for handheld |
Carbon Steel (0.5–4.0 mm)
| Thickness (mm) | Wire Ø (mm) | Wire Feed (mm/s) | Peak Power (%) | Scan Width (mm) | Frequency (Hz) |
|---|---|---|---|---|---|
| 0.5 | — | — | 23 | 1.5 | 150 |
| 0.8 | 0.8 | 18 | 33 | 2.5 | 100 |
| 1.0 | 0.8 | 18 | 38 | 2.5 | 100 |
| 1.2 | 1.0–1.2 | 15 | 38 | 3.0 | 100 |
| 1.5 | 1.2 | 12 | 40 | 3.0 | 100 |
| 2.0 | 1.2 | 12 | 67 | 3.5 | 30 |
| 2.5 | 1.2 | 10 | 70 | 4.0 | 30 |
| 3.0 | 1.6 | 8 | 85 | 4.5 | 30 |
| 4.0 | 1.6 | 6 | 95 | 4.5 | 25 |
Aluminium (1.0–2.0 mm)
Aluminium has high thermal conductivity and reflectivity. Correct focus and gas flow are essential.
| Thickness (mm) | Wire Ø (mm) | Wire Feed (mm/s) | Peak Power (%) | Scan Width (mm) | Focus (mm) | Frequency (Hz) |
|---|---|---|---|---|---|---|
| 1.0 | 1.0 | 15 | 50 | 2.5 | +3 | 100 |
| 1.2 | 1.0–1.2 | 13 | 55 | 2.5–3.0 | +3 | 80 |
| 1.5 | 1.2 | 12 | 70 | 3.0 | +3 | 40 |
| 2.0 | 1.6 | 10 | 85 | 4.0 | +5 | 40 |
For all aluminium tests, nitrogen flow was maintained at ≥20 L/min. In many cases 25–30 L/min further improves protection and reduces soot.
How Parameters Influence Weld Quality
Penetration Depth
Penetration increases when:
- Peak power is increased
- Scan width is reduced
- Travel speed or wire feed is reduced
On 3 mm carbon steel, for example, moving from 70 % to 85 % peak power with a 4.5 mm wobble width is often the difference between partial and full penetration.
Bead Width & Appearance
Bead width grows when:
- Wobble scan width is increased
- Wire diameter and feed are increased
- Frequency is adjusted for a smoother oscillation
For cosmetic stainless seams on 1.0–1.5 mm sheet, many users prefer 3.0 mm wobble with 60–100 Hz to obtain a wide, bright seam with very low spatter.
Quick troubleshooting map (what to adjust first)
Check gas flow (≥20 L/min), nozzle position, focus stability, and reduce excessive wobble width.
Lower peak power first, then increase wobble width, and keep travel consistent; avoid too-low frequency on thin parts.
Increase penetration reserve (peak power / narrower scan), ensure joint fit-up, and verify wire diameter/feed.
Use focus +3~+5 mm, increase N₂ flow (25–30 L/min), and stabilize wobble/frequency.
Example Parameter Sets
1.5 mm Stainless Steel – Visible Corner Seam
- Laser power: 1200 W
- Wire: 1.2 mm, 13 mm/s
- Peak power: 40 %
- Scan width: 3.0 mm at 60–100 Hz
- Gas: nitrogen ≥20 L/min, focus at surface
This setting produces a smooth, low-distortion corner weld suitable for doors and cabinets. Grinding can often be eliminated, saving significant finishing time compared to TIG.
2.0 mm Carbon Steel – Structural Fillet
- Laser power: 1200 W
- Wire: 1.2 mm, 12 mm/s
- Peak power: 67 %
- Scan width: 3.5 mm at 30 Hz
- Gas: nitrogen ≥20 L/min
Compared with MIG, this parameter window offers similar or higher strength with less spatter and a much smaller HAZ, reducing distortion on long fillet welds.
2.0 mm Aluminium – Housing and Frame Parts
- Laser power: 1200 W
- Wire: 1.6 mm, 10 mm/s
- Peak power: 85 %
- Scan width: 4.0 mm at 40 Hz
- Focus: +5 mm above surface, nitrogen ≥25 L/min
With correct focus and gas flow, aluminium welds show reduced soot and porosity compared with conventional TIG, especially on long continuous seams.
Recommended next steps
Handheld laser welding guide — process, materials, joint types, and selection.
Shielding gas for laser welding — nitrogen vs argon, flow, and defects.
Laser welding problems & solutions — porosity, burn-through, weak strength.
Wire feed guide — wire size, feed rate, gap filling.
Related technical articles
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