Why is Aluminum so Hard to Weld?
Unlike stainless steel, aluminum hates lasers. It has high thermal conductivity (heat runs away fast) and high reflectivity (it bounces the laser beam back).
This means a 1000W laser often isn't enough to "bite" into the material instantly. You get a weak weld, or worse, you damage your laser lens from the reflection.
The 1500W Rule
For smooth aluminum welding, we strongly recommend a minimum of 1500W power. The extra punch breaks through the oxide layer instantly.
The Golden Parameter Chart (2026)
Stop guessing. Use these starting points for 5xxx and 6xxx series aluminum.
*Values based on 1500W Laser Source + Sup20s Head.
| Thickness | Power | Speed | Wobble | Gas (Argon) |
|---|---|---|---|---|
| 1.0 mm | 600W (40%) | 15 mm/s | 1.2mm / 12Hz | 15 L/min |
| 2.0 mm | 1000W (65%) | 10 mm/s | 1.6mm / 10Hz | 18 L/min |
| 3.0 mm | 1500W (100%) | 6 mm/s | 2.0mm / 8Hz | 20 L/min |
Troubleshooting Guide
- Weld is Black/Sooty: Your gas coverage is poor.
Fix: Increase Argon flow to 15-20L/min. Check for breeze blowing gas away. Bring nozzle closer. - Porosity (Tiny Holes): Surface contamination.
Fix: Clean aluminum with acetone or stainless wire brush before welding. Oil/Grease = Hydrogen Bubbles. - Crack at the End (Crater Crack): Heat stops too suddenly.
Fix: Set "Ramp Down" time to 200ms in your controller settings.