Twenty-seven calculators, selectors and reference tables for setup, troubleshooting, weld design, consumables, production, and power planning. Use the numbers as practical engineering aids, then verify WPS, manufacturer, and electrical requirements for the job at hand.
Starting values, parameter relationships, unit conversions, and diagnostic troubleshooting.
Amperage from thickness via the 1-amp-per-0.001" rule, plus wire feed speeds for 0.023"–0.045" wire.
Open Tool →kJ/mm from volts, amps, and travel speed — with preheat and interpass temperature guidance.
Open Tool →Current ranges for GMAW, GTAW, SMAW, FCAW, and SAW by wire, electrode, and tungsten size.
Open Reference →Calculate travel speed from weld length and welding time, or determine welding time from speed.
Open Tool →GTAW and GMAW CFH ranges by cup and wire size, plus a live CFH↔L/min converter.
Open Tool →Relate wire feed speed, consumed length, mass, and continuous feed time from wire geometry.
Open Tool →Diagnose porosity, spatter, undercut, lack of fusion and more — process-specific checks from setup to equipment.
Diagnose →Simple geometry and material estimates for planning work.
Gauge to inch to millimeter reference for common sheet steel thicknesses.
Open Reference →Calculate fillet weld leg size, effective throat, and approximate weld cross-sectional area from basic joint dimensions.
Open Tool →Estimate ideal weld volume and deposited mass from fillet, area, or rectangular geometry.
Open Tool →Planning estimate for pass count from joint geometry and assumed bead area — must follow the qualified WPS.
Estimate Passes →Wire, filler, gas, and deposition planning estimates.
E6010 through E7024 positions, polarity, amperage by size, and applications.
Open Reference →Match common filler metals to base metals and applications.
Open Reference →Estimate welding wire or electrode consumption from weld size, weld length, deposition efficiency, and consumable data.
Open Tool →Approximate wire length, mass per meter, and theoretical feed time from spool data.
Open Tool →Estimate gas use, cylinders, remaining fraction, and optional cost from arc-on time.
Open Tool →Calculate gross wire mass feed and deposited weld metal rate from wire data.
Open Tool →Separate arc time, elapsed time, capacity, and job cost for clearer planning.
Estimate welding cost from consumables, shielding gas, electricity, labor, and welding time.
Open Tool →Estimate arc time by travel speed or deposition rate, then add editable elapsed-time assumptions.
Open Tool →Estimate joints per shift, total capacity, and staffing from user-entered production assumptions.
Open Tool →Decision-support tools for choosing processes and defining machine requirements.
Compare SMAW, GMAW, FCAW, GTAW and SAW with transparent scores, trade-offs and automation potential for your application.
Select Process →Translate application needs into required machine class, duty, input power and feeder requirements — no brands invented.
Define Requirements →Planning aids for machine input, generator demand, duty cycle, and output cable voltage drop.
Estimate the generator capacity required for a welding machine based on input voltage, phase, current, and machine power requirements.
Open Tool →Combine verified input loads with visible simultaneity, auxiliary load, and reserve assumptions.
Open Tool →Estimate welding-machine input kVA, kW, energy, and optional electricity cost.
Open Tool →Understand rated arc-on minutes and a clearly labelled inverse-square duty-cycle estimate.
Open Tool →Compare user-entered cable resistance, rating, voltage drop, and power loss data.
Open Tool →