HOW TO CALCULATE WELDING CONSUMABLE FOR Any ITEM
FORMULA FOR CALCULATION OF WELDING CONSUMABLE -
W = A x e x L X 1/EA = cross-sectional area of weld metal deposited
e = density (7.8gr/cm3)
L = length of welding (cm)
E = deposition efficiency (n) for SMAW- 0.55 to 0.80
MIG- 0.95
FCAW- 0.90
SAW- 1.0
FOR EXAMPLE A WELD OF L= 100 CM AND SINGLE V GROOVE AND ROOT FACE F= 3MM, ROOT GAP R= 2MM, BEVEL ANGLE 60 DEGRE, PLATE THICKNESS T=10MM
PROCESS = SMAW
A= (RXT) + (T-F) ² X TAN Ø/2
A = (2X10) + (10-3) ² X TAN (60/2)
A = 0.48CM ²
W = A X e X L X 1/E
W = 0.48 X 7.8 X 100 X 1/0.55
W = 680.864 gr
add reinforcement = 20%
W = 816 gr for 100cm length welding
similarly, calculate the area for any weld and put value in the above formula
1) SOME STANDARD WEIGHT FOR GMAW (SOLID WIRE) IS AS UNDER-
(only for reference)
PLATE TH MM DOUBLE V KG/M SINGLE V KG/M
10 0.462 0.593
20 1.42 2.12
25 2.08 3.23
30 2.85 4.58
32 3.19 5.18
40 4.74 7.97
45 5.87 10.050 7.11 12.3
100 25.9 48.0
2) GMAW SOLID WIRE, AND SMAW PROCESS.
BEVEL IN ONE PLATE ,
CONSUMABLE WEIGHT IN Kg/MTR
IN MM consumable weight in kg/meter
10 0.377 0.472
12 0.497 0.971
16 0.777 0.971
20 1.11 1.39
22 1.3 1.62
25 1.6 2.0
28 1.94 2.42
30 2.18 2.73
32 2.43 3.04
36 2.98 3.73
40 3.59 4.48
45 4.41 5.52
50 5.33 6.66
100 19.1 23.8
3) FILLET WELD, GMAW SOLID WIRE ,
IF REINFORCEMENT = 1MM
LEG LENGTH CONSUMABLE
IN MM WEIGHT IN KG/MTR
5 0.257
6 0.357
7 0.473
8 0.606
9 0.754
10 0.919
11 1.1
12 1.3
15 1.99
18 2.82
20 3.46
25 5.34
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CALCULATION FOR FILET WELD
process- SMAW
WELD LENGTH = 100CM
CROSS SECTION AREA = (a x b)/2
A = 6 X 6 / 2
= 18mm²
or 0.18cm²
W = A x e x L x 1/E
W = 0.18 X 7.85 X100 X 1/0.55
for SMAW E = 0.55 MIG = 0.95
FCAW= 0.90
SAW= 1.0
W = 255.27gr
add reinforcement 20% (1.2)
w = 255.25 x 1.2
w = 306.32 gr + 10% westage
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