Weld metal and consumable calculator
A fillet weld is a triangular prism. Its throat, area and volume all follow from the leg length.
kg/h
%
%
Deposited weld metal
0.424kg
- Consumable to buy
- 0.499
- Design throat thickness
- 4.243
- Weld cross-section
- 18.00 mm2
- Arc time
- 0.121 hours
- Total job time at that duty cycle
- 0:18:10
- Implied travel speed
- 412.8 mm/min
- Weld metal volume
- 54.00 cm3
Show the working
- Fillet leg length = 6
- Weld length = 3000
- Deposition rate = 3.5
- Deposition efficiency = 85
- Arc-on time = 40
- Design throat thickness = 6 * 0.7071067811865476 = 4.242 64
- Weld cross-section = 6^2 / 2 = 18
- Weld metal volume = 18 * 3000 / 1000 = 54
- Deposited weld metal = 54 * 7.85 / 1000 = 0.4239
- Consumable to buy = 0.4239 / (85/100) = 0.498 706
- Arc time = 0.4239 / 3.5 = 0.121 114
- total_hours = 0.121 114 / (40/100) = 0.302 786
- Total job time at that duty cycle = 0.302 786 * 3600 = 1090.03
- Implied travel speed = 0.121 114 > 0 ? 3000 / (0.121 114 * 60) : 0 = 412.833
Values are shown to six significant figures here; the arithmetic itself runs on exact fractions and is only rounded where a number is printed.
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The formula
- fillet area = leg^2 / 2, throat = leg / sqrt 2
- weight = area x length x steel density
- consumable = deposited weight / deposition efficiency
Deposition efficiency is about 95% for solid wire MIG, 85% for flux-cored and 60 to 70% for stick electrodes with stub loss.
Doubling the leg length quadruples the weld metal. Oversized fillets are the classic hidden cost in fabrication.