Welding Deposition Rate Calculator
Carbon Steel (Solid Wire)
Stainless Steel
Aluminum
Flux Cored (Steel)
Metal Cored (Steel)
Common sizes: 0.023, 0.030, 0.035, 0.045, 0.052, 0.062 (1/16)
Inches Per Minute (IPM)
MIG (Solid): 95-98% | Flux Cored: 80-85% | Stick: 55-65%
Deposition Rate (Imperial):
0.00 lbs/hr
Deposition Rate (Metric):
0.00 kg/hr
Wire Consumed (8hr Shift):
0.00 lbs
Understanding Welding Deposition Rate
The welding deposition rate is a critical metric in manufacturing and fabrication that measures how much filler metal is actually deposited into the weld joint per hour. It is one of the primary indicators of welding productivity.
Unlike the burn-off rate (which is simply how much wire is melted), the deposition rate accounts for efficiency losses due to spatter, slag, and fume generation. Accurately calculating this rate helps in estimating project costs, scheduling timelines, and ordering the correct amount of consumables.
The Math Behind the Calculation
This calculator uses the geometric volume of the wire combined with the material density to determine the weight deposited over time. The core formula is:
Deposition Rate (lb/hr) = 13.1 × (Diameter)² × Wire Feed Speed × Efficiency × Density Factor
Where:
- Diameter is measured in inches.
- Wire Feed Speed (WFS) is measured in Inches Per Minute (IPM).
- Efficiency is the percentage of wire that becomes part of the weld (expressed as a decimal).
Typical Deposition Efficiencies
Different welding processes have inherent waste factors. Use the table below to estimate your efficiency percentage if you are unsure:
| Welding Process | Typical Efficiency | Waste Source |
|---|---|---|
| Submerged Arc (SAW) | 99% – 100% | Minimal loss |
| MIG / GMAW (Solid Wire) | 92% – 98% | Minor spatter |
| FCAW (Gas Shielded) | 80% – 85% | Slag and spatter |
| Stick / SMAW | 55% – 65% | Stub loss, slag, spatter |
Factors Influencing Deposition
To increase your deposition rate, you typically need to increase amperage and wire feed speed. However, simply cranking up the settings isn't always feasible. High deposition rates can lead to weld defects like lack of fusion or undercut if the travel speed isn't adjusted accordingly. The diameter of the wire also plays a huge role; thicker wires can generally deposit more metal but may require equipment capable of higher amperage outputs.