Filler Metal Consumption Calculator
Accurately estimate the total weight of filler metal (electrodes, wire) needed for your welding project to improve cost estimation and procurement.
Calculation Inputs
Provide the total weld volume and the deposition efficiency of your process.
Budgeting for Welds: The Cost of Consumables
In large-scale fabrication, the cost of filler metal can be a significant portion of the total project budget. Being able to accurately estimate how much material you will consume is essential for competitive bidding and profitable project management. This tool helps you do just that by accounting for the single most important factor in consumption calculation: deposition efficiency.
The Formula: Deposited vs. Purchased
Required Weight = (Weld Volume × Density) / Deposition Efficiency
- Weld Volume: The total volume of all the weld joints in your project. This needs to be calculated separately based on the joint design (e.g., fillet size, groove angle).
- Density: The density of the weld metal (for steel, this is approximately 7.85 g/cm³).
- Deposition Efficiency: This is the crucial factor. It's the ratio of the weight of the metal deposited in the weld to the weight of the consumable used. No process is 100% efficient due to losses from spatter, slag, fumes, and stub ends (for stick electrodes).