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Calculatingweldvolumeandweight
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Calculatingthevolumeofaweldisoneofthefirststepstobetakenwh

Withthisinformation,andknowingthedepositionrateoftheprocess,it
lengthoftimethatanarcisburninganddepositingweldmetal)andthe
fillthejoint.Bothofthesearerequiredinordertocalculatethecostof
futureJobKnowledgearticles.

Determiningthevolumeofaweldrequiressomeknowledgeofbasicgeo
theweldandmultiplythisfigurebyitslength.Thefirststepthenistoc

Withafilletweldora45singlebeveljointthisisrelativelysimplebutt
preparationbecomesmorecomplex.Fig.1illustrateshowsimplethisca
theareaofsuchaweldishalfthesquareoftheleglength,Z.Whenusi
seldomdepositpreciselythesizeofweldcalleduponthedrawingorin
someexcessweldmetalonthefaceoftheweld.

Fig.1.Areaofanequalleg
lengthfilletweld

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4/27/2017 CalculatingweldvolumeandweightJobKnowledge95

Anasymmetricalfilletweldisalittlemoredifficulttheareaofatriangle
dividedby2sowhenafilletweldisdepositedwithunequalleglengths
thethroat,a,bythelengthofthefaceIanddividedby2asillustrated

Fig.2.Areaofanunequalleg
lengthfillet

Turningnowtobuttwelds,thecalculationsbecomealittlemorecomple

Therearethreefactorsthatdeterminethevolumeoftheweldinasingl
bevel,b,theexcessweldmetalandtherootgap,g,asillustratedinFig
tobeabletoaddtogethertheareasofthefourcomponentsillustratedi

Fig.3.Thefourareasofasingle
buttweld

Thedimension'c'isgivenby(tanbxt)theareaofasingleredtriangl
thetworedregionsaddedtogethercanbecalculatedusingtheformula

Thewidthoftheweldcap,w,isgivenbyW=2(tanbxt)+g.
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4/27/2017 CalculatingweldvolumeandweightJobKnowledge95

Theareaoftheexcessweldmetalisapproximatedbytheformula(Wx

Theareaprovidedbytherootgapbygxt.

Thebevelangles,b,mostoftenusedare10=(tan0.176),15=(tan
0.637)and45=(tan1.00).Aswillbecomeobviouswhentheweighti
decimalpointisintherightplaceifcentimetresareusedinthecalculat

Asaworkedexample,iftheweldisinaplate2.5cmthickness,0.3cmro
32.5=0.637)andwithacapheightof0.2cmwehave:

1.c=tan32.5x2.5=0.637x2.5=1.59cm
2.w=2(0.637x2.5)+0.3=3.485cmsotheareaofthecap=(3.
3.areaoftheorangearea=0.3x2.5=0.75sq.cm.
4.areaofthetworedareas=2x(1.59x2.5)/2=3.97sq.cm.

Thisgivesatotalareaof5.07sqcm.Thevolumecanthenbecalculated
areaensuringthatthislengthisalsogivenincentimetres!

Conventionally,thevolumeisoftenexpressedincubiccentimetres(cu.c
is507cu.cm/metre.

Toobtaintheweightofweldmetalthisfigureisthenmultipliedbythed
ofsomeofthemorecommonalloysingm/cu.cm.Notethatwithsomea
densityquitesignificantly.

Table1.Densitiesofsomeofthemorecommonalloys.

Density(gm/cm3)
Alloy
iron 7.87
0.25%carbonsteel 7.86
12%Crsteel 7.70
304stainlesssteel 7.92
nickel 8.90
80/20Ni.Cr 8.40
625typealloy 8.44
copper 8.94
70/30brass 8.53
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4/27/2017 CalculatingweldvolumeandweightJobKnowledge95

7%Albronze 7.89
aluminium 2.70
Al5052 2.65
Al7075 2.8
Theweightofweldmetaltofillonemetrelengthofthejointdescribeda
x7.86)=3985gmsor3.98kgs/metreina5XXXseriesaluminiumalloy

CalculatingtheweightofweldmetalindoublesidedVjointsusesthesa
individual'V'sandaddingtheproducts.

AJpreparation,however,addsanotherareaintotheequationthatoft
Fig.4.Theformulaegivenabovetocalculate'c',theareaofthetwored
remainunchangedbutthewidthofthecapmustbeincreasedby2r.Th
calculateandthetwowhiterootradiusareastobeaddedtothetotal.

Fig.4.Single'U'preparation(oth
notationasinFig.3)

Therelevantformulaearethus:

1.thedimension'c'isgivenby(tanbx(tr))thetotalareaofthe
formula2((tr)(tanbx(tr))/2or((t.r)(tanbx(tr)).
2.thewidthoftheweldcap,w,isgivenbyw=2(tanbx(tr))+g
3.theareaoftheexcessweldmetalisgivenbytheformula(wxh
4.thearea'A'is(tr)x(2r+g).
5.thearea'B'isgxr.
6.therootradiusareais(r2)/4

ForadoubleUpreparationitisnecessarytocalculatetheareasofboth
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4/27/2017 CalculatingweldvolumeandweightJobKnowledge95

Havingcalculatedtheweightofweldmetalrequiredtofillaweldprepar
offillermetalrequired(thesetwofiguresarenotnecessarilythesame)
thisweldmetalbothessentialinordertoarriveatacostoffabricating
Knowledgearticles.

ThisarticlewaswrittenbyGeneMathers.

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