How To Calculate Filler Metal Consumption

Source: HOBART Filler Metals Released: June 30, 1999

Site: http://www.mwsco.com/kb/kb_frameset.asp?ArticleID=111

The following tables will help you estimate electrode qu antity and cost for a variety of joints. The bases for the tabulations are explained below. Should you encounter a variation in conditions or joint preparation that is not shown in the tables, substitute appropriate figures in the W = D / (1 K) formula and calculate it. Electrode requirements have been calculated as follows: W = D / (1 K) Where, W = Weight of electrodes required D = Weight of steel deposited K = Total electrode losses To arrive at the weight of steel deposited, it is necessary to calculate first the volume of deposited metal (area of the groove multiplied by the length). Then this volumetric value is converted to weight by the factor 0.283 pounds per cubic inch for steel. Where weld reinforcement is involved, it is added to the requirements for net, unreinforced welds. These figures are based on the efficiency of the process used. On square and "V" groove joints, the figures are based on stick electrode efficiency. For tubular wire results, divide steel deposit weight by 0.80 and for solid wire divide by 0.90.

Size of fillet

Steel deposited per linear foot of weld (lbs.) 0.027 0.063 0.106 0.166 0.239 0.425 0.663 0.955 1.698 Stick* .049 .114 .193 .302 .434 .773 1.205 1.736 3.087

Pounds of electrodes required per linear foot of weld* (approx.) Tubular .034 .079 .133 .208 .298 .531 .829 1.194 2.123 Solid .03 .07 .118 .184 .265 .472 .737 1.061 1.890

S e e F i g u r e 1

L (in inches) 1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 1

*Includes scrap end and spatter loss

Figure 1

Joint dimensions (in inches)

Steel deposited per linear foot of weld

Pounds of electrodes required per linear foot of weld* (approx.) With reinforcement** 0.16 0.20 0.23 0.26 0.27 0.30 0.21 0.24 0.36 0.39 0.47 0.53

S e e F i g u r e 2

MTL. THICK 3/16 1/4 5/16

BEAD T WIDTH B 3/8 7/16 1/2

ROOT OPEN G 0 1/16 1/16 3/32 1/16 3/32 0 1/32 1/32 1/16 1/16 3/32

Without reinWith reinWithout forcement(lbs.) forcement(lbs.) reinforcement -----0.020 0.027 0.039 0.033 0.050 -----0.013 0.020 0.040 0.053 0.080 0.088 0.109 0.129 0.143 0.153 0.170 0.119 0.132 0.199 0.218 0.261 0.288 -----0.04 0.05 0.07 0.06 0.09 -----0.03 0.04 0.07 0.10 0.14

1/8 3/16 1/4

1/4 3/8 7/16

Figure 2

S e e F i g u r e 3

Joint Dimensions (in inches) MTL. THICK T 1/4 5/16 3/8 1/2 5/8 3/4 1 BREAD WIDTH B 0.207 0.311 0.414 0.558 0.702 0.847 1.138 ROOT OPEN G 1/16 3/32 1/8 1/8 1/8 1/8 1/8

Pounds of electrodes Steel deposited per linear foot required per linear foot of of weld weld* (approx.) Without reinforcement (lbs.) 0.085 0.173 0.282 0.489 0.753 1.088 1.930 With reinforcements** (lbs.) 0.143 0.258 0.394 0.641 0.942 1.320 2.240 0.15 0.31 0.50 0.87 1.35 1.94 3.45 0.25 0.46 0.70 1.15 1.68 2.35 4.00 Without reinforcement With reinforcement**

*Includes scrap end and spatter loss. **R=Height of reinforcement.

Figure 3