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Tool 10 · Consumables

CONSUMABLE CONSUMPTION

How many kilos of wire or rods does a job actually eat? Weld metal volume, deposition efficiency, and a waste allowance — worked out before you order, not after you run out mid-shift.

ESTIMATE CONSUMABLE USE

Density follows the deposited metal, not the process — steel FCAW wire and steel stick rods use steel density.

Weld Size Input

Results appear here. Enter values and hit Calculate.

THE FORMULAS

Mass = Area × Length × Density

Deposited weld metal

Purchased = Deposited ÷ Efficiency

× (1 + waste) if a waste factor is set

Not every gram you buy ends up in the weld. Spatter, slag, electrode stubs, and spool tails never make it into the joint — the deposition efficiency accounts for the loss.

Deposited volume = cross-section × length. Mass = volume × density. Density follows the deposited metal — carbon steel 7.85, stainless ~7.9, aluminum 2.70 g/cm³ — and is auto-assigned from the material pick.

ASSUMPTIONS — ALL EDITABLE

  • Leg → AreaFillet leg mode assumes an equal-leg 90° fillet: area = leg² ÷ 2. Use area mode for any other joint.
  • EfficiencyDefaults: solid wire 95%, flux-cored 85%, stick 60%. Typical shop numbers — adjust to your consumable's data sheet.
  • DensityAuto-assigned from Material / Alloy: steel 7.85, stainless 7.90, aluminum 2.70, copper 8.96 g/cm³. Density belongs to the deposited metal — flux-cored and stick use the wire's metal composition, not a process constant. Pick “Custom / other alloy…” for unusual alloys.
  • WasteZero unless you enter a factor. Add 5–15% for stubs, spatter, and rework on real jobs.

WHY EFFICIENCY DIFFERS

The same weld needs different purchased weights depending on the process. This is why the assumption is visible instead of buried.

Solid Wire — ~95%

Nearly everything off the spool lands in the weld. Loss is mostly spatter and wire toss. The highest-efficiency option of the three.

Flux-Cored — ~85%

The slag layer and some fume take a share of the wire weight. Outershield-style wires are still economical because of deposition rate.

Stick — ~60%

Rod stub loss plus flux coating weight that never deposits. You buy more kilograms than you lay down — that's baked into the number.

Typical values for carbon steel consumables. Exact figures come from the manufacturer's data sheet for your specific product — treat these as a starting point.

USING THE ESTIMATE

Ordering, Not Certifying

Use this to size a spool, a box of rods, or a quote. It is not a substitute for manufacturer consumable data or a qualified welding procedure.

Waste Is Real

Rods lose stubs, wire loses spatter, and rework loses both. A 10% waste factor on a production job is not pessimism — it's shop experience.

Area Is the Weak Link

Actual weld size is almost never the perfect triangle. For critical quantities, measure the real reinforcement and penetration profile instead of assuming perfect geometry.

Welding Cost Calculator → Weld Size Calculator → Travel Speed Calculator →

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