Welding
Filler metal weight calculator
In short
Filler metal weight comes from the joint section A, the weld length L and the density ρ: deposited weight m = A × L × ρ. The filler to allow for is M = m / (η / 100), with η the deposition efficiency of the process; for covered electrodes, the number of electrodes comes from the ESAB datasheets.
Calculation
Example calculated with the tool’s default values.
Inputs
- Joint type
- Butt, single V groove
- Plate thickness
- 10 mm
- Groove angle (included)
- 60°
- Root face
- 2 mm
- Root gap
- 2 mm
- Reinforcement
- 2 mm
- Weld length
- 1000 mm
- Material
- Carbon steel
- Process
- MIG/MAG, solid wire (131, 135)
Results
- Filler weight to allow for
- 0.59 kg
Worked example
Every value in this section belongs to the example, calculated with the tool’s default values.
Other results of the example
- Wire to order
- 0.59 kgkg of wire or rod
- Deposited weight
- 0.565 kg
- Joint section
- 71.9mm²
- Deposition efficiency
- 95%Lincoln C4.200 : court-circuit ≥ 93 %, jet axial / pulsé 98 % (retenu 95 %)
- Deposited weight per metre
- 0.565 kgper metre of weld
- Geometric estimate: theoretical joint section, with no start-up losses, repairs or gouging. Allow a margin depending on the shop.
- Indicative values: they do not replace the qualified WPS.
Step-by-step calculation
Groove depth
d = t − c
10.0 − 2.0 = 8.0 mm
Width at the surface
W = g + 2·d·tan(α/2)
2.0 + 2 × 8.0 × tan 30.0° = 11.2 mm
Groove and gap section
A₁ = g·t + d²·tan(α/2)
2.0 × 10.0 + 8.0² × 0.5774 = 57.0 mm²
Reinforcement
A₂ = (2/3)·W·h
2/3 × 11.2 × 2.0 = 15.0 mm²
Total section
A = A₁ + A₂
57.0 + 15.0 = 71.9 mm²
Deposited weight
m = A × L × ρ
71.9 mm² × 1000 mm × 7850 kg/m³ = 0.565 kg
Filler to allow for
M = m / (η / 100)
0.565 / 0.95 = 0.594 kg
How to use it
- Pick the joint: single V butt, double V butt, or fillet weld with its throat a.
- Enter the thickness, the included groove angle, the root face, the root gap and the reinforcement (or the throat and the number of runs).
- Enter the weld length and the material.
- Pick the process, and for covered electrodes the type and diameter; enter a known efficiency if needed.
- Read the filler weight to allow for.
Frequently asked questions
How do I calculate weld metal weight?
Example: single V on 10 mm steel, 60°, 2 mm root face, 2 mm root gap, 2 mm reinforcement. Section A = 57.0 + 15.0 = 71.9 mm². Over 1000 mm, the deposited weight is 71.9 mm² × 1000 mm × 7850 kg/m³ = 0.565 kg. In MAG with 95 % efficiency, allow 0.565 / 0.95 = 0.594 kg of wire.
How is the area of a single V groove calculated?
With d = t − c the groove depth and W = g + 2·d·tan(α/2) the width at the surface, the groove and gap section is A₁ = g·t + d²·tan(α/2). The reinforcement, taken as a parabolic segment, adds A₂ = (2/3)·W·h. For a symmetric double V, d = (t − c) / 2 and both sides are counted.
How do I calculate the weight of a fillet weld?
The fillet is taken as an isosceles triangle with throat a: section A₁ = a² per run (leg z = a·√2, A = z²/2). With n runs, A = n × A₁, then m = A × L × ρ. A convex fillet adds metal.
How many electrodes per metre of weld?
The calculation multiplies the deposited weight by the number of electrodes per kg of deposited metal from the ESAB datasheets, rounded up. Basic OK 48.00 Ø 3.2 × 350 mm: 70 % efficiency and 42 electrodes per kg deposited; rutile OK 46.00 Ø 3.2: 65 % and 53 electrodes per kg.
Which deposition efficiency for each process?
Default values, in the middle of the quoted ranges: MIG/MAG solid wire 95 % (Lincoln: 93 to 98 %), gas-shielded flux-cored wire 85 %, metal-cored wire 96 %, TIG 95 %, submerged arc 99 % (flux excluded). For covered electrodes, the efficiency comes from the ESAB datasheet for each diameter. A known efficiency can be entered, from 30 to 100 %.
Limits
Indicative results: geometric estimate of the theoretical joint section, with no start-up losses, repairs or gouging; allow a margin depending on the shop. The weld metal is assumed to have the same density as the part. Above a 4 mm root gap, check the WPS (usual gap 1 to 4 mm). The values do not replace the qualified WPS.
Sources
- Géométrie du joint : Section trapézoïdale du chanfrein + segment parabolique 2/3·W·h pour la surépaisseur ; angle : a²
- Masses volumiques: src/calc/data/materials.ts (EN 10365, EN 10088-1, …)
- ESAB OK 48.00 et OK 46.00, Deposition Data (rendement, électrodes par kg déposé) : Fiches produit ESAB (link)
- Lincoln Electric : Gas Metal Arc Welding, Product and Procedure Selection (C4.200) : Electrode Efficiencies : 93 à 98 % (link)
- Welding Answers : rendements de dépôt par procédé : FCAW-G 82–88 %, MCAW 94–98 %, GTAW 94–97 %, SAW 99 % (link)