SAW Flux Consumption Calculator
Estimate the amount of flux required for a Submerged Arc Welding (SAW) job based on the amount of wire to be consumed and the flux-to-wire ratio.
The Role of Flux in Submerged Arc Welding
In Submerged Arc Welding (SAW), the arc is "submerged" under a blanket of granular fusible material called flux. The flux melts to form a protective slag layer that shields the weld from the atmosphere, cleanses the molten metal, and can add alloying elements. After welding, the unfused flux is recovered, but the melted slag is discarded. Accurately estimating flux consumption is vital for cost control and material planning in large-scale SAW operations.
The Flux-to-Wire Ratio
This is the ratio of the weight of flux consumed to the weight of wire melted. It is not 1:1 because not all the flux melts. A typical ratio for general-purpose SAW is around 1.1, meaning for every 10 kg of wire used, about 11 kg of flux will be consumed (melted slag + recovered flux). This ratio can change based on amperage, voltage, and joint design.