Enter the wire diameter and feed speed to get the hourly weight of wire the feeder pulls through, then apply the deposition efficiency to see the rate at which metal actually goes into the joint. Add the weight of weld metal required and the page also returns arc time, the wire weight needed and the number of spools.
The method multiplies the wire cross section by the feed speed to get a volume, then multiplies by density to reach a weight, using only circular area and conservation of mass, so no reference document is involved. The cross section and the consumption rate are reported separately so the figures can be checked by hand. Figures current as of October 2026.
Default values for deposition efficiency and wire density are not confirmed by an authoritative source, so none are offered and you enter your own from manufacturer data or recorded performance. The spool count is rounded up once at the end and the label says so. Working out consumption from a groove cross section, shielding gas consumption and heat input are not covered. This calculator is for reference and does not replace design. Review by a qualified engineer is required.
Frequently Asked Questions
It varies with the process and the wire type and is not confirmed by an authoritative source, so no default is offered. Use the figure from the wire manufacturer or your own recorded performance.
Consumption is the total hourly weight of wire the feeder pulls through, while the deposition rate is the part that actually ends up in the joint. The ratio between them is the deposition efficiency, and spatter and stub loss make up the difference.
No. Arc time counts only the period the arc is burning. Setup, slag removal and travel are not included, so the real working time is longer.