Free Welding Calculator
Calculate filler metal weight for fillet and V-groove welds — with deposition efficiency for SMAW, GMAW, FCAW, and SAW. Imperial and metric.
A = 0.25² ÷ 2 = 0.03125 in² · V = 0.03125 × 120 = 3.75 in³ · W_theoretical = 3.75 × 0.283 = 1.06 lbs · W_actual = 1.06 ÷ 0.90 = 1.18 lbs MIG wire
Same theoretical 1.06 lbs · W_actual = 1.06 ÷ 0.60 = 1.77 lbs of electrodes — 50% more than MIG due to stub loss and slag.
tan(30°) = 0.577 · A = (0.0625 + 0.5 × 0.577) × 0.5 − (0.0625² ÷ (4 × 0.577)) = 0.176 in² · V = 0.176 × 36 = 6.34 in³ · W_actual = (6.34 × 0.283) ÷ 0.95 = 1.89 lbs SAW wire
First calculate the triangular cross-section: area = leg² ÷ 2. Then multiply by weld length to get volume. Multiply volume by steel density (0.283 lb/in³) and divide by the process deposition efficiency (0.90 for MIG, 0.60 for stick). A 1/4 inch fillet weld 10 feet long needs about 1.2 lbs of MIG wire.
Not all filler metal ends up in the weld. SMAW covered electrodes are only 55-65% efficient — the remainder becomes slag, stub loss, and spatter. Solid MIG wire is 88-95% efficient. Using the correct efficiency for your process prevents under-ordering consumables. A 10-foot 1/4 inch fillet weld requires ~1.2 lbs of MIG wire but ~2.0 lbs of stick electrodes.
Convex bead shape adds about 20% to theoretical cross-section (1.2× factor). In production, actual consumption runs 1.3–1.5× theoretical due to spatter, stub loss, and variable fit-up. This calculator uses theoretical values; add 20-30% buffer for your actual order.
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