TOOLS / WELDING

Weld consumable quantity calculator

Estimate weld metal and consumable weight for a fillet or single-V joint, so electrodes or wire can be ordered without running short.

Weld metal required0.14 kg
Consumable to order0.20 kg

Weld cross-section: 18.0 mm2. Consumable allows for 70% deposition efficiency; reinforcement, spatter, stub loss and rework are not included unless you add them to the efficiency.

Planning estimate for ordering and costing. Confirm the actual joint preparation, reinforcement and process efficiency from the WPS and filler maker data.

Formula

Fillet cross-section = leg squared / 2. Single-V cross-section = thickness x root gap + thickness squared x tan(included angle / 2). Weld metal (kg) = cross-section (mm2) x length (mm) x 7.85 x 10 to the power -6. Consumable (kg) = weld metal / deposition efficiency.

Standard / source

Weld cross-section geometry with steel density 7.85 g/cm3 and filler-maker deposition efficiency data, as summarised in the MetalCalz tool-expansion research (2026-10-27). Efficiency varies by process and electrode, so enter the value for the actual consumable.

Worked example

Fillet leg 6 mm, length 1000 mm, efficiency 70%: cross-section = 36 / 2 = 18 mm2. Weld metal = 18 x 1000 x 7.85 x 10 to the power -6 = 0.14 kg. Consumable = 0.1413 / 0.70 = 0.20 kg. These are the calculator defaults.

Safety note

Planning estimate for ordering and costing only. It does not set welding parameters or qualify a weld. Confirm joint preparation, reinforcement and process efficiency from the WPS and filler maker data before production welding.