🔥 Welding Calculator
Enter your fillet weld leg size, total weld length, and process details to estimate deposited weld metal weight, filler consumption, and welding time.
What This Calculator Does
This calculator estimates how much deposited weld metal a fillet weld requires, how much filler wire or electrode you’ll need after accounting for deposition losses, and roughly how long the actual arc-on welding time will take.
The Formula
For an equal-leg fillet weld, the cross-sectional area is half the leg size squared (0.5 x leg^2), based on a right-triangle weld profile. Multiplying that area by the total weld length gives the deposited metal volume, which is converted to weight using mild steel density (7.85 g/cm^3). Because not all filler wire fed ends up in the joint, the deposited weight is divided by the process deposition efficiency to estimate total wire consumption, and dividing wire needed by the deposition rate estimates arc-on welding time.
Good to Know
- Deposition efficiency and deposition rate vary by process (SMAW, GMAW/MIG, FCAW, SAW) and settings — use figures from your welding procedure specification (WPS) or equipment manufacturer for best accuracy.
- This tool gives a general planning estimate for material and time budgeting, not a substitute for a qualified welding procedure or inspection.