Welding Deposition Rate Calculator
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Welding Deposition Rate Calculator
Material Type (Density)
Carbon Steel (0.283 lbs/in³)
Stainless Steel (0.284 lbs/in³)
Aluminum (0.098 lbs/in³)
Titanium (0.163 lbs/in³)
Copper (0.323 lbs/in³)
Wire Diameter (inches)
0.023″ (0.6 mm)
0.030″ (0.8 mm)
0.035″ (0.9 mm)
0.045″ (1.2 mm)
0.052″ (1.3 mm)
1/16″ (1.6 mm)
5/64″ (2.0 mm)
3/32″ (2.4 mm)
1/8″ (3.2 mm)
Custom…
Enter Custom Diameter (inches)
Process Efficiency (%)
GMAW – Solid Wire (MIG) ~98%
FCAW – Flux Core ~85%
MCAW – Metal Core ~82-92%
SMAW – Stick Electrode ~65%
SAW – Submerged Arc ~100%
Custom Efficiency…
Enter Custom Efficiency (%)
Calculate Deposition Rate
Deposition Rate (Imperial)
0.00 lbs/hr
Deposition Rate (Metric)
0.00 kg/hr
Total Wire Consumption (Melt-off Rate)
0.00 lbs/hr
This is the wire usage from the spool before waste/spatter loss.
Understanding Welding Deposition Rate
The Deposition Rate is a critical metric in welding economics and productivity analysis. It measures how much weld metal is actually deposited into the joint per unit of time (typically pounds per hour or kilograms per hour). Unlike the "Melt-off Rate," which measures how much wire is consumed, the Deposition Rate accounts for losses due to spatter, slag, and fume generation (Process Efficiency).
The Formula
The calculation is based on the volume of wire fed through the welding gun, the density of the material, and the efficiency of the transfer process.
Deposition Rate (lbs/hr) = 13.1 × (Diameter)² × WFS × Density × Efficiency
Where:
Diameter: The wire diameter in inches.WFS: Wire Feed Speed in Inches Per Minute (IPM).Density: The weight of the material per cubic inch (e.g., steel is approx 0.283 lbs/in³).Efficiency: The percentage of filler metal that becomes part of the weldment (expressed as a decimal).
Typical Process Efficiencies
Different welding processes have varying levels of waste. Selecting a process with higher efficiency can significantly reduce filler metal costs.
Process
Typical Efficiency
Waste Factors
Submerged Arc (SAW)
99% – 100%
Minimal loss, flux covers arc.
GMAW (Solid Wire MIG)
95% – 98%
Minor spatter loss.
FCAW (Flux Core)
80% – 85%
Slag formation and spatter.
SMAW (Stick)
60% – 65%
Stub loss, heavy slag, spatter.
Why Calculate Deposition Rate?
1. Cost Estimation: Knowing the deposition rate helps in bidding for jobs by estimating the exact time required to complete welds.2. Productivity Benchmarking: It allows shop managers to compare current throughput against theoretical maximums.3. Consumable Purchasing: Helps calculate how much wire needs to be ordered for a specific project based on total weld volume required.
Example Calculation
If you are welding Carbon Steel with 0.045″ solid wire at a wire feed speed of 400 IPM using the GMAW process (98% efficiency):
Wire Area: π × (0.045/2)² ≈ 0.00159 in²Volume/hr: 0.00159 in² × 400 IPM × 60 min = 38.17 in³/hrMelt-off Rate: 38.17 × 0.283 lbs/in³ ≈ 10.8 lbs/hrDeposition Rate: 10.8 lbs/hr × 0.98 ≈ 10.58 lbs/hr
// Helper to toggle custom inputs
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var select = document.getElementById("wireDiameter");
var customGroup = document.getElementById("customDiameterGroup");
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document.getElementById("efficiency").onchange = function() {
var select = document.getElementById("efficiency");
var customGroup = document.getElementById("customEffGroup");
if (select.value === "custom_eff") {
customGroup.style.display = "block";
} else {
customGroup.style.display = "none";
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};
function calculateDepositionRate() {
// 1. Get Material Density
var density = parseFloat(document.getElementById("materialType").value);
// 2. Get Diameter
var diameterSelect = document.getElementById("wireDiameter").value;
var diameter = 0;
if (diameterSelect === "custom") {
diameter = parseFloat(document.getElementById("customDiameterInput").value);
} else {
diameter = parseFloat(diameterSelect);
}
// 3. Get Wire Feed Speed
var wfs = parseFloat(document.getElementById("wireFeedSpeed").value);
// 4. Get Efficiency
var effSelect = document.getElementById("efficiency").value;
var efficiency = 0;
if (effSelect === "custom_eff") {
efficiency = parseFloat(document.getElementById("customEffInput").value);
} else {
efficiency = parseFloat(effSelect);
}
// Validation
if (isNaN(density) || isNaN(diameter) || isNaN(wfs) || isNaN(efficiency)) {
alert("Please enter valid numeric values for all fields.");
return;
}
if (diameter <= 0 || wfs < 0 || efficiency 100) {
alert("Please check your input values. Efficiency must be between 0-100, and other values positive.");
return;
}
// LOGIC
// Convert efficiency to decimal
var effDecimal = efficiency / 100;
// Calculate Cross Sectional Area (A = pi * r^2)
// r = diameter / 2
var radius = diameter / 2;
var area = Math.PI * Math.pow(radius, 2); // Square inches
// Calculate Volume per Hour
// Volume (in^3/hr) = Area (in^2) * WFS (in/min) * 60 (min/hr)
var volumePerHour = area * wfs * 60;
// Calculate Melt-off Rate (lbs/hr) – Theory (before efficiency loss)
// Weight = Volume * Density
var meltOffRate = volumePerHour * density;
// Calculate Actual Deposition Rate (lbs/hr)
var depositionRateLbs = meltOffRate * effDecimal;
// Convert to Metric (kg/hr)
// 1 lb = 0.453592 kg
var depositionRateKg = depositionRateLbs * 0.453592;
// Display Results
document.getElementById("resultContainer").style.display = "block";
document.getElementById("resImperial").innerText = depositionRateLbs.toFixed(2) + " lbs/hr";
document.getElementById("resMetric").innerText = depositionRateKg.toFixed(2) + " kg/hr";
document.getElementById("resConsumption").innerText = meltOffRate.toFixed(2) + " lbs/hr";
}