The weld metal deposition rate is the mass of filler metal deposited per unit time (kg/h). Knowing the deposition rate allows welding engineers to calculate weld time, filler metal consumption per joint, and production cost per metre of weld. This calculator covers GMAW (MIG/MAG), FCAW, SMAW, and SAW processes using wire feed speed, electrode diameter, and process efficiency factors.
Weld Metal Deposition Rate Calculator
Formula: DR (kg/h) = (π/4) × d² × WFS × ρ × 60 × (duty/100) × η_dep
where d = wire diameter (cm), WFS = wire feed speed (cm/min), ρ = density (g/cm³)
Deposition efficiency η_dep: SAW ~99%, GMAW solid ~95–98%, FCAW-G ~85–90%, SMAW ~65–85%, FCAW-S ~80–87%
Deposition Rate Reference Table — Typical Values by Process
| Process | Wire/Electrode Dia. | Typical Current | Deposition Rate | Dep. Efficiency |
|---|---|---|---|---|
| GMAW solid (MIG) | 1.0–1.6 mm | 150–280 A | 2–6 kg/h | 95–98% |
| GMAW metal-cored | 1.2–1.6 mm | 180–350 A | 3–8 kg/h | 90–95% |
| FCAW-G (gas-shielded) | 1.2–2.0 mm | 200–400 A | 3–10 kg/h | 82–90% |
| FCAW-S (self-shielded) | 1.6–3.2 mm | 200–500 A | 3–9 kg/h | 78–87% |
| SMAW (stick) | 2.5–5.0 mm | 80–220 A | 0.5–3.0 kg/h | 60–85% |
| SAW (single wire) | 2.4–5.0 mm | 300–1000 A | 5–25 kg/h | 97–99% |
| SAW (tandem wire) | 2 × 3.2–4.0 mm | 500–1500 A total | 15–45 kg/h | 97–99% |
Using Deposition Rate for Weld Cost Estimation
Once you know the deposition rate, you can calculate the weld metal required per joint, the time to complete a weld, and the filler metal cost:
- Weld metal volume per joint (cm³): Cross-sectional area of the weld pass(es) × total weld length
- Weld metal mass per joint (kg): Volume × density / 1000
- Arc time required (h): Weld metal mass / (deposition rate × deposition efficiency)
- Total time (h): Arc time / (duty cycle / 100) — accounting for repositioning, wire changes, inter-pass inspection
- Filler metal cost: Wire consumed (kg) × price per kg
For multi-pass welds, repeat the calculation for each pass size and sum the totals. Most weld cost estimation software (e.g. Lincoln VRTEX, Miller Weld Setting Calculator) uses this same approach.
Improving Deposition Rate in Production
- Upgrade from SMAW to GMAW/FCAW: Up to 5–10× deposition rate improvement with equivalent weld quality
- Increase duty cycle: Pre-positioning fixturing, automated wire feed, efficient inter-pass cleaning
- Larger diameter wire at higher current: SAW with 4mm wire at 800A achieves >15 kg/h vs 5 kg/h for 2.4mm at 400A
- Metal-cored wire: Higher deposition efficiency than flux-cored, lower spatter than SMAW; ideal for robotic GMAW
References
- Lincoln Electric, The Procedure Handbook of Arc Welding. 14th ed. The Lincoln Electric Company, 2000.
- AWS A5.18/A5.18M:2021 Specification for Carbon Steel Electrodes and Rods for Gas Shielded Arc Welding.
- Miller Electric, Weld Cost Calculator Methodology. Appleton, WI, 2019.
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