Weld metal and consumables calculator
Enter the joint type, dimensions and weld length. The calculator gives the weld cross-section, the deposited weld metal, the filler metal needed after deposition losses, the arc time and the shielding gas consumption, for estimating and costing welding work.
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What it calculates
- Weld cross-section for fillet (throat a), single-V, double-V and square butt joints
- Deposited weld metal in kg, including reinforcement
- Filler metal needed from deposition efficiency (solid wire, flux-cored, SAW, stick)
- Arc time from deposition rate, and shielding gas from flow rate
Formulas
Fillet: A = a² (leg z = a·√2) Single-V: A = t·g + (t − c)²·tan(α/2) Double-V: A = t·g + (t − c)²·tan(α/2) / 2 Square: A = t·g A_total = A × (1 + reinforcement) m = A_total × ρ × L ; filler = m / efficiency ; arc time = m / deposition rate
Worked example
A 5 mm fillet weld (a = 5) with 10 % reinforcement has A = 27.5 mm², which is about 0.22 kg of steel weld metal per metre.
How to use it
- Create a free account with Google or e-mail.
- Open the calculator and enter your values; units can be metric or imperial.
- Read the result with its formula and source, and export to PDF, DXF or CSV where available.
Free account with Google or e-mail
Frequently asked questions
How much welding wire do I need per metre?
Divide the deposited weld metal by the deposition efficiency of the process: about 0.95 for solid MAG wire, 0.85–0.9 for flux-cored wire and lower for stick electrodes.
Is throat or leg length used for fillet welds?
The throat thickness a. For an equal-leg fillet weld the leg length is z = a·√2.
Can I use it for stainless or aluminium?
Yes. Change the density (7.9 g/cm³ for stainless, 2.7 g/cm³ for aluminium).
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- Heat input check and t8/5 cooling timeChoose the two base metals, process and filler, then enter preheat and the welding parameters for each run.
Results are engineering estimates for planning. They do not replace the applicable standard, a qualified procedure or a check by a qualified engineer.