How to use this calculator
- Enter weld geometry. Use total weld length, fillet leg size and one or two weld sides.
- Enter material and rate. Use deposited metal density and an effective deposited metal rate.
- Set efficiency. Use deposition efficiency to estimate filler consumed from deposited weld metal.
- Read mass and time. Use deposited mass, filler mass and arc time for early production planning.
How it works
For a simple equal-leg fillet weld, the deposited cross-section is estimated as a right triangle:
A = 0.5 x z^2 x weld_sides
Weld volume is that area times length. Mass follows from deposited metal density:
V = A x L
m_deposited = V x density
Arc time uses the deposited metal rate, while filler mass adjusts for deposition efficiency:
time = m_deposited / deposition_rate
m_filler = m_deposited / eta
Worked example
Verified against the live calculator
A 1 m single-sided fillet weld with a 6 mm leg has
about 18 mm^2 of weld area and 18 cm^3 of deposited
volume. With steel density near 7850 kg/m^3, deposited metal is
about 0.141 kg. At 2 kg/h deposition rate, arc
time is about 4.2 minutes.
Frequently asked questions
How do you estimate weld metal deposited?
For an equal-leg fillet weld, the cross-section area is approximately 0.5 x leg size squared for each weld side. Multiply by weld length and density to get deposited metal mass.
How is welding arc time estimated?
Arc time is deposited weld metal divided by the entered deposited metal rate. It is arc-on time only, not total labor time.
What does deposition efficiency do?
Deposition efficiency estimates filler consumed from deposited metal. Filler required equals deposited mass divided by efficiency.
Does this work for groove welds?
This page is for simple equal-leg fillet weld estimates. Groove welds, bevels, root openings and backing geometry need their own volume calculation.
Method & assumptions
- Equal-leg fillet weld area is approximated as 0.5 x leg size squared per side.
- Arc time is arc-on time only. Fit-up, tack welds, cleaning, repositioning, starts/stops, inspection and rework are not included.
- Overweld, convexity, root gaps, bevels, groove weld volume, spatter and stub loss need separate allowances.
- Use welding heat input, weld throat and weld group for adjacent procedure and strength checks.