Laser Welding & EV Busbar

Adjustable Ring Mode (ARM) Laser Wobble & Power Ratio Calculator

Model dual-beam concentric fiber laser power distribution, high-frequency wobble trajectories, and keyhole hydrodynamic stability for spatter-free welding.

Process & CAM Parameters

Total Fiber Laser Power (P_total in W):

Combined center core + outer ring laser power.

Core Power Percentage (% P_core):

30% Core (1200 W) 70% Ring (2800 W)

Welding Travel Speed (v in mm/s):

Wobble Oscillation Frequency (f in Hz):

Wobble Width / Amplitude (W_w in mm):

Wobble Trajectory Pattern:

Engineering Calculations

Linear Heat Input

50.0J/mm

Wobble Step Pitch

0.20mm

Keyhole Peclet No.

1.85Pe

Spatter Suppression

94.2%

Dynamic CAM Toolpath & Vector Preview

Need complete manufacturing prepress guidance and formulas?

Read the Full Laser ARM Wobble & Beam Shaping Guide →

Engineering Principles & Formulations

Adjustable Ring Mode (ARM) fiber lasers utilize a dual-beam core/ring concentric architecture to independently control keyhole vaporization depth and molten pool hydrodynamic stability. By balancing the keyhole aspect ratio with outer ring preheating and high-frequency galvanometer wobble scanning, zero-spatter copper-to-aluminum EV battery busbars and hairpin motor stator welds are achieved.

Linear Heat Input ($E_{\text{linear}}$): Calculated as $E = \frac{P_{\text{total}}}{v}$. Controlled to prevent burn-through on thin battery foil tabs.
Wobble Step Pitch ($P$): Defined as $P = \frac{v}{f}$. Values below $0.25\text{ mm}$ ensure smooth seam overlap without transverse scalloping.
Keyhole Peclet Number ($Pe$): Governed by $Pe = \frac{v \cdot d_{\text{core}}}{2 \alpha}$, where $\alpha$ is material thermal diffusivity. Ring preheating lowers thermal gradients, keeping $Pe$ in the hydrodynamic laminar conduction-keyhole transition zone.