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Estimate electrodes, MIG/MAG wire, flux-cored wire, TIG rod and SAW wire from the cross-section of fillet, single-V, double-V and K joints. Enter welds one by one or upload a whole weld list in Excel, with shop-practice factors and contingency.
m (kg) = A × L × 7.85 / 1000 / deposition efficiency
| # | Description / Location | Joint type | t | b | p | Angle° | z | A input | L (m) | Qty | Material | Process | Total A (mm²) | Weld metal (kg) | Consumable (kg) | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Subtotal | 0 | 0 | ||||||||||||||
| Contingency 10% | 0 | |||||||||||||||
| Grand total | 0 | |||||||||||||||
Grey cells are not used for that joint type. Dimensions in mm, length in m. Cap: · Contingency — change in Settings.
| Welding process | Material | Rows | Weld metal (kg) | Efficiency | Consumable (kg) | Contingency (kg) | Total (kg) | Pack size | Packs |
|---|
Excel file with the columns, drop-down lists for joint type / material / process, and instructions.
Enter data in the yellow cells from row 5 down. One row per weld (or group of identical welds).
Results appear in the “Weld list” tab, where you can edit and export again.
Oversize: added to the leg z of every fillet (area grows with the square). Tabs: added at both ends of each weld length. Back-gouging: % added to the area of X and K joints to refill the gouged root. Contingency then only covers interpass grinding, repairs, tacks, test pieces and damaged electrodes.
By h (mm): cap area = ⅔ × W × h, where W is the groove opening width (fillet: W = z·√2, with its own convexity); X and K joints have a cap on both sides. Contingency is added as a separate line at the bottom (repairs, waste, test pieces…).
| Process | Deposition efficiency (%) | Pack size (kg) | Unit |
|---|
Deposition efficiency = weld metal deposited / consumable used; for SMAW it allows for stub ends, slag and spatter. Defaults follow the efficiency table of the AWI Weld Consumable Calculator — adjust to your shop's practice.
The weight of electrodes (or wire) follows from the amount of metal that has to be deposited in the joint, divided by the deposition efficiency of the welding process. The calculator above works through five steps:
| Joint type | Geometric area A | Notes |
|---|---|---|
| Fillet | z² / 2 | z is the leg length; if the drawing gives the throat a, z = a × √2 |
| Square butt (I) | t · b | t thickness, b root gap |
| Single-V butt | t·b + (t − p)² · tan(α/2) | α included angle, p root face |
| Double-V butt (X) | t·b + (t − p)²/2 · tan(α/2) | root face p at mid-thickness |
| Single bevel (1/2V) | t·b + (t − p)² · tan β / 2 | β bevel angle of one plate |
| Double bevel (K) | t·b + (t − p)² · tan β / 4 | one plate bevelled on both sides |
Deposition efficiency is the share of the consumable that ends up as weld metal. The values below are common reference figures; calibrate them against your own shop's issue records.
| Process | Efficiency |
|---|---|
| SMAW – rutile electrode (E6013) | 56% |
| SMAW – low-hydrogen electrode (E7018) | 59% |
| SMAW – iron powder electrode (E7024) | 60% |
| GMAW – MIG/MAG short arc / spray / pulsed | 92% / 95% / 98% |
| FCAW – flux-cored wire (E71T-1) | 85% |
| FCAW – metal-cored wire (E70C-6M) | 92% |
| GTAW – TIG | 98% |
| SAW – submerged arc | 99% |
Inputs: t = 12 mm, root gap b = 2 mm, root face p = 2 mm, 60° included angle, cap height h = 2 mm, 40 mm run-on/run-off tab at each end.
Part of each electrode never reaches the weld: the stub end (about 5 cm per rod), the flux coating that turns into slag, and spatter. Only around 56–60% of the electrode weight becomes weld metal. Solid MIG/MAG wire loses far less (92–98%).
In Quick calc choose Fillet and type the throat into the a field — z updates automatically (z = a × √2). In the Excel template enter the leg z (= a × 1.414).
Yes. Download the Excel template from the “Import Excel” tab, enter one weld per row and upload it. Results appear in the “Weld list” tab with a summary by process, number of boxes/spools, and an Excel export.
Keep the contingency for hard-to-quantify losses only: interpass grinding, repairs, tacks, test pieces, damp electrodes. Larger items — fillet oversize, run-on/run-off tabs, back-gouging — have their own settings; adjust those to your practice instead of inflating the contingency.
No. All calculations and Excel parsing run locally in your browser.
Results are estimates for budgeting and ordering welding consumables. Actual consumption depends on welder skill, position, fit-up quality and each shop's welding procedure (WPS).