How to use this calculator
- Enter wire size and feed speed. Use filler wire diameter and wire feed speed.
- Enter density and efficiency. Use filler density and deposition efficiency for the process.
- Enter target deposit. Use the deposited weld metal mass target for an arc-time estimate.
- Read rate and time. Use deposited rate, filler feed rate and arc time for early production planning.
How it works
Wire feed starts with the filler wire cross-section:
A = pi x d^2 / 4
Wire volume feed rate is area times wire feed speed:
Vdot = A x WFS
Filler mass rate uses filler density, and deposited metal rate applies deposition efficiency:
mdot_filler(kg/s) = Vdot(mm^3/min) x 1e-9 x density / 60
mdot_deposited = mdot_filler x eta
arc_time = target_deposit / mdot_deposited
Worked example
Verified against the live calculator
A 1.0 mm steel wire at 6000 mm/min feeds about
2.22 kg/h of filler. With 90% deposition efficiency,
deposited metal rate is about 2.0 kg/h. A
0.25 kg deposited-metal target takes about
7.5 minutes of arc-on time.
Frequently asked questions
How do you calculate deposition rate from wire feed speed?
Calculate wire cross-section area from diameter, multiply by wire feed speed to get volume per minute, then multiply by filler density. Deposited rate applies deposition efficiency.
Is wire feed speed the same as deposition rate?
No. Wire feed speed is length per minute. Deposition rate is mass per time after wire diameter, density and deposition efficiency are accounted for.
Does this calculate welding current?
No. Wire-feed-speed-to-current relationships depend on process, wire, polarity, stickout, transfer mode and power source. This calculator only estimates wire and deposited metal rate.
How should I use the arc time result?
Treat it as arc-on time for the entered deposited mass. Fit-up, starts/stops, cleaning, repositioning, inspection and duty cycle are not included.
Method & assumptions
- Assumes round solid wire and uses density x wire volume feed rate.
- Deposition efficiency is user-entered and process-specific.
- Does not calculate current, voltage, heat input, transfer mode, duty cycle, starts/stops, fit-up or operator time.
- Use welding amperage, welding deposition, weld cost per inch, groove weld area, welding heat input and weld throat for adjacent weld estimating, planning and strength checks.