Laser Welding Wobble Geometry & Seam Energy Density Calculator
Calculate linear heat input ($J/mm$), galvanometer wobble beam trajectory, molten pool overlap percentage, seam width, and power ramping vectors for fiber laser seam welding (IPG, Trumpf, Precitec, Keyence, Han's Laser).
1. Laser & Material Setup
2. Galvanometer Wobble Parameters
Weld Pool Energy & Trajectory Metrics
💡 CAM Prepress Tip: For closed circular or rectangular hermetic seams, include a 3.0–5.0mm tangential overlap vector with laser power linear ramp-down to 0% to prevent crater crack formation at the seam termination.
Laser Wobble Pattern Selection Matrix
| Wobble Pattern | Geometry Formula | Key Advantages | Best Applications |
|---|---|---|---|
| Circular (O) | x = R cos(ωt), y = R sin(ωt) | Uniform heat distribution, lowest porosity | Hermetic battery cans, 316L tubes, medical seals |
| Figure-8 (∞) | x = R sin(2ωt), y = R sin(ωt) | Dual center pass, wide root penetration | Dissimilar metals (Copper to Aluminum), high-thermal alloys |
| Transverse Line (—) | x = 0, y = A sin(ωt) | Maximum gap bridging across butt joints | Sheet metal chassis, stamping assemblies with loose fitup |
| Spiral / Vortex (@) | r(t) = (R/2)(1 + sin(ωt/2)) | Deep keyhole stabilization, zero spatter | Thick plate welding (> 3mm) and spot-welding clusters |
1. Linear Heat Input vs Travel Speed
Linear heat input ($H = P / v$) governs the thermal volume and heat-affected zone (HAZ). Excessive heat causes thermal distortion and burn-through in thin foil tabs; insufficient heat causes lack of fusion (cold laps).
2. Preventing Keyhole Collapse & Porosity
Galvo wobble oscillation agitates the molten keyhole, preventing vapor bubble entrapment. High wobble frequencies (200–500 Hz) create stable hydrodynamic vortex flow, reducing internal gas pores by up to 90% in aluminum alloys.
3. DXF Vector Path Continuity
Laser welding controllers require continuous 2D/3D polyline vectors. Any micro-gap or duplicate node in the DXF file triggers an unintended laser shutoff and restart cycle, creating heavy blowholes and seam defects.
4. Crater Crack Prevention & Overlap Routines
At the end of a closed hermetic vector loop, abruptly turning off the laser freezes the melt pool instantly, causing a shrinkage crater crack. Prepress vectors must include an overlap lead-out tangent with a synchronized power attenuation decay.