Laser welding wire feed speed calculator
Estimate filler-wire feed speed, wire length per seam, batch consumption and wire mass from welding speed, wire diameter, joint geometry and deposition efficiency.
- Butt and fillet geometry
- m/min and mm/s output
- Per-part and batch usage
- No registration required
Balance filler volume with welding travel speed
Estimate a starting wire feed from the volume that must be deposited along the joint. Confirm the result with actual bead shape, fusion, metallurgy and wire-feeder stability.
Understand the volume balance behind wire feed speed
The calculator balances the wire volume entering the process with the filler volume required along each millimeter of joint.
Awire = π × diameter² ÷ 4Calculates the solid cross-sectional area of the selected round filler wire.
Vfill = filler area × travel speedConverts joint filler cross-section and forward speed into deposited volume per second.
F = Vfill ÷ (wire area × efficiency)Estimates the wire movement needed to supply the required deposited volume.
Lwire = feed/travel ratio × seam lengthEstimates the wire length consumed for each seam before batch multiplication.
Choose the filler-area method that matches the joint
Geometry inputs describe added filler volume, not total fused base metal. Use drawings or a representative cross-section for the strongest estimate.
Gap plus reinforcement
The calculator adds root-gap volume and the estimated surface reinforcement profile.
- Measure the real gap range
- Use the filled joint depth
- Estimate bead width and height
Leg-size estimate
A right-triangle estimate uses half of the leg size squared, then applies a profile adjustment.
- Confirm effective throat requirement
- Check convex or concave profile
- Review penetration contribution
Use a measured section
Enter filler cross-section directly when CAD, macro sections or established production data are available.
- Separate filler from fused base metal
- Average representative sections
- Include acceptable process variation
See how wire diameter changes required feed speed
For the same filler volume, a smaller wire must move faster. Final diameter also depends on feeder capability, melting stability, alloy availability and bead control.
| Wire Diameter | Wire Area | Relative Feed Needed | Common Planning Direction | What To Check |
|---|---|---|---|---|
| 0.8 mm | 0.50 mm² | 1.56× the feed of 1.0 mm wire | Fine filler control and smaller joints | Feeder speed range and wire stiffness |
| 1.0 mm | 0.79 mm² | Reference | General starting diameter for many trials | Alloy, gap, bead target and torch setup |
| 1.2 mm | 1.13 mm² | About 0.69× the feed of 1.0 mm wire | Higher filler volume at lower linear feed | Melting stability and beam-to-wire position |
| 1.6 mm | 2.01 mm² | About 0.39× the feed of 1.0 mm wire | Larger filler demand and engineered applications | Source power, joint size and feeder compatibility |
See what changes when you adjust wire and joint inputs
Change one factor at a time and confirm bead shape, fusion and cross-section on the actual joint.
| Parameter Change | Calculated Effect | Possible Weld Effect | What To Verify |
|---|---|---|---|
| Increase travel speed | Raises required wire feed proportionally | Can reduce local heating time while increasing feeder demand | Fusion, bead continuity and feeder response |
| Increase wire diameter | Lowers linear feed for the same filler volume | Changes melting behavior and wire stiffness | Beam position, power margin and transfer stability |
| Increase joint gap | Raises filler cross-section and feed demand | Can increase lack-of-fusion or bead-shape risk | Fixture, edge preparation and process suitability |
| Reduce deposition efficiency | Raises calculated wire feed allowance | Represents transfer loss or process variation | Whether the assumed efficiency matches test data |
| Increase fillet leg size | Raises area approximately with the square of leg size | Rapidly increases filler volume and heat demand | Required throat, pass strategy and joint design |
Turn the calculated speed into a stable welding trial
A correct volume calculation can still produce a poor weld when the wire approaches the beam at the wrong position, angle or timing.
Align beam, wire and joint
- Keep the wire tip in a stable melt location
- Confirm leading or trailing orientation
- Prevent contact with the workpiece
- Maintain repeatable stand-off
Match feeder response
- Check acceleration at seam start
- Coordinate start and stop timing
- Avoid slipping and wire buckling
- Verify long-seam speed stability
Tune from the cross-section
- Inspect bead width and reinforcement
- Check edge fusion and undercut
- Review porosity and inclusions
- Record accepted parameter windows
Confirm wire feed on your actual joint
Send material, wire alloy, diameter, joint drawing, gap tolerance, welding speed and acceptance requirement. Oceanplayer can help review feeder direction and sample-weld results.
Share geometry
Provide joint dimensions, gap range, wire and expected bead profile.
Set a starting feed
Balance wire volume with travel speed, power and melting behavior.
Inspect and tune
Review surface, section, fusion, stability and repeatability.
Continue your laser welding calculation
Use wire feed together with power selection, heat input, shielding gas and the complete welding guide.
Laser welding wire feed questions
Use these answers to interpret the result and prepare a controlled filler-wire trial.