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P=(W×L)÷E

How to calculating required welding

wire ?

Welding Process
How to calculating required welding wire ?

One of our task in mechanical work is Welding. Good engineer should know how
to prepare his work. In this case is calculating welding rod. Before the engineer
calculating welding rod, engineer must be understand about:
a. Technical Drawing,
b. Welding code.
Ok, lets us started to explain how to calculating welding rod/wire requirement
from the simple welding.

First step, we must find the volume of welding, usually we used triangular
pyramid to simplify the calculation. example : we have data from welder about
Area, Long & Thickness as bellow :

In this case for example the width of las is 8 mm, then we can compute:
Surface Area (A) = ½ x 8 x 8 mm = 32 mm2

Las Volume 1 meter long for welding (V) = A x L = 32 mm x 1000 mm = 32,000

mm 3 = 32 cm3

So,
If the Specific Gravity = 7.85 gr/cm3 Mild Steel, then
Heavy Metal Las to 1 meter = 32 x 7.85 = 251.2 g = 0.251 Kg / mtr.
How to count applies to the form - the form of connection such as: U type,
Double V butt joint type or without a groove.
Counts above applies to connections without reinforcement. If there is a
reinforcement, then the amount of welding wire, plus about 3%.

CALCULATING NEEDS WELDING WIRE

To calculate the required welding wire used the formula:

G (The number of Las Wire) = GL x P / DE

GL = Heavy Metals Las per Unit Length (Meters)

P = Total length Connections Las
DE = Deposition Efficiency

Deposition Efficiency What is it ??????

Deposition Efficiency is the ratio between the amount of metals produced by
Number Las welding wire used and expressed in percent.

Las DE = Heavy Metal (Weld Metal) / Weight Las wire used (Electrode Used)

Typically, data Deposition Efficiency is issued by the respective manufacturer of

welding wire, but the average mean value (Average Value) Deposition Efficiency
for each welding process is as follows:

Deposition Process Welding% Eff

 SAW 99%
 GMAW (98% Ar, 2% O2) 98%
 GMAW (75% Ar, 25% CO 2) 96%
 GMAW (99.99% CO 2) 93%
 Metal Core Wire 93%
 FCAW (Gas-Shielded) 86%
 FCAW (Self Shielded) 78%
 SMAW (length 300 mm) 59%
 SMAW (length 350 mm) 62%
 SMAW (length 450 mm) 66%

Note:
For SMAW Process, the rest is wasted electrode 5 cm / Trunk.
If we return to the above case,
Heavy Metals Las per meter is: 0.251 Kg / Meter
Its long-las = 1000 m
The amount of weld metal = 0.251 x 1000 = 251 Kg.

The amount of welding wire to be ordered in accordance with the welding process
used is as follows:

Las Wire Welding Processes that Ordered (Kg)

 SAW 253 Kg
 GMAW (98% Ar, 2% O2) 256 Kg
 GMAW (75% Ar, 25% CO 2) 261 Kg
 GMAW (99.99% CO 2) 270 Kg
 Metal Core Wire 270 Kg
 FCAW (Gas-Shielded) 292 Kg
 FCAW (Self Shielded) 322 Kg
 SMAW (length 300 mm) 425 Kg
 SMAW (length 350 mm) 404 Kg
 SMAW (length 450 mm) 380 Kg

Note:
For SMAW Process, the rest is wasted electrode 5 cm / Trunk.

Calculating weld volume and weight

Job Knowledge
Calculating the volume of a weld is one of the first steps to be taken when estimating the
cost of making a weld.

With this information, and knowing the deposition rate of the process, it is possible to
determine the arc time (the length of time that an arc is burning and depositing weld
metal) and the amount of welding consumables required to fill the joint. Both of these are
required in order to calculate the cost of making the weld. Costing will be dealt with in
future Job Knowledge articles.

Determining the volume of a weld requires some knowledge of basic geometrical

calculations to determine the area of the weld and multiply this figure by its length. The
first step then is to calculate the cross sectional area of the joint.

With a fillet weld or a 45° single bevel joint this is relatively simple but the calculations
become lengthier as the weld preparation becomes more complex. Fig.1 illustrates how
simple this calculation is for an equal leg length fillet weld; the area of such a weld is half
the square of the leg length, Z. When using this formula do not forget that welders seldom
deposit precisely the size of weld called up on the drawing or in the welding procedure and
that there may be some excess weld metal on the face of the weld.

Fig.1. Area of an equal leg length fillet weld

An asymmetrical fillet weld is a little more difficult; the area of a triangle is given by the
base Z2 times the height Z1 divided by 2 so when a fillet weld is deposited with unequal leg
lengths the area can be calculated from multiplying the throat, a, by the length of the face
I and divided by 2 as illustrated in Fig.2.

Fig.2. Area of an unequal leg length fillet

Turning now to butt welds, the calculations become a little more complex.

There are three factors that determine the volume of the weld in a single V butt weld.
These are the angle of the bevel, b, the excess weld metal and the root gap, g, as
illustrated in Fig 3. To calculate the area of this weld we need to be able to add together
the areas of the four components illustrated in Fig.3.

Fig.3. The four areas of a single-V butt weld

The dimension 'c' is given by (tan b x t); the area of a single red triangle is therefore t(tan
b x t)/2. The total area of the two red regions added together can be calculated using the
formula 2t(tan b x t)/2 or t(tan b x t).

The width of the weld cap, w, is given by W = 2(tan b x t) + g.

The area of the excess weld metal is approximated by the formula (W x h)/2.

The area provided by the root gap by g x t.

The bevel angles, b, most often used are 10° = (tan 0.176), 15° = (tan 0.268), 22.5° =
(tan 0.414) 32.5° = (tan 0.637) and 45° = (tan 1.00). As will become obvious when the
weight is calculated, it is easier to ensure that the decimal point is in the right place if
centimetres are used in the calculations rather than millimetres.

As a worked example, if the weld is in a plate 2.5cm thickness, 0.3cm root gap, 65°
included angle (b = 32.50°; tan 32.5° = 0.637) and with a cap height of 0.2cm we have:-

1. c = tan32.5 x 2.5 = 0.637 x 2.5 = 1.59cm

2. w = 2(0.637x2.5) + 0.3 = 3.485cm so the area of the cap = (3.485x0.2)/2 =
0.348 sq. cm.
3. area of the orange area = 0.3 x 2.5 = 0.75 sq.cm.
 4. area of the two red areas = 2 x (1.59 x 2.5)/2 = 3.97sq.cm.

This gives a total area of 5.07sq cm. The volume can then be calculated by multiplying the
length of the weld by the area - ensuring that this length is also given in centimetres!

Conventionally, the volume is often expressed in cubic centimetres (cu.cm). per metre so
in this example the volume is 507 cu. cm/metre.

To obtain the weight of weld metal this figure is then multiplied by the density of the
alloy. Table 1 gives the density of some of the more common alloys in gm/cu.cm. Note
that with some alloys the alloying elements can change the density quite significantly.

Table 1. Densities of some of the more common alloys.

Alloy Density (gm/cm3)

iron 7.87

0.25% carbon steel 7.86

12%Cr steel 7.70

304 stainless steel 7.92

nickel 8.90

80/20 Ni.Cr 8.40

625 type alloy 8.44

copper 8.94

70/30 brass 8.53

7% Al bronze 7.89

aluminium 2.70

Al 5052 2.65

Al 7075 2.8

The weight of weld metal to fill one metre length of the joint described above would
therefore be; in carbon steel (507 x 7.86) = 3985gms or 3.98kgs/metre; in a 5XXX series
aluminium alloy (507 x 2.65) = 1343gms, 1.34kgs/metre.

Calculating the weight of weld metal in double sided V-joints uses the same approach by
dividing the weld into its individual 'V's and adding the products.

A J-preparation, however, adds another area into the equation; that of the half circle at
the root of the weld, see Fig.4. The formulae given above to calculate 'c', the area of the
two red components and the excess weld metal remain unchanged but the width of the
cap must be increased by 2r. There are also the two areas, 'A' and 'B', to calculate and the
two white root radius areas to be added to the total.
 Fig.4. Single 'U' preparation (other notation as in Fig.3)

The relevant formulae are thus:

1. the dimension 'c' is given by (tan b x (t-r)); the total area of the two red regions is
therefore given by the formula 2((t-r)(tan b x (t-r))/2 or ((t.-r)(tan b x (t-r)).
2. the width of the weld cap, w, is given by w = 2(tan b x (t-r)) + g +2r.
3. the area of the excess weld metal is given by the formula (w x h)/2.
4. the area 'A' is (t-r) x (2r +g).
5. the area 'B' is g x r.
6. the root radius area is (πr2)/4

For a double-U preparation it is necessary to calculate the areas of both sides and add
these together.

Having calculated the weight of weld metal required to fill a weld preparation it is then
possible to calculate the weight of filler metal required (these two figures are not
necessarily the same) and to estimate the time required to deposit this weld metal; both
essential in order to arrive at a cost of fabricating the weld. This will be covered in future
Job Knowledge articles.

This article was written by Gene Mathers.