FORMULA AND ASSUMPTIONS
Equal-leg fillet area is leg size squared divided by 2, an ideal right-triangle profile. Custom area uses your measured or specified value. Rectangular area is width x depth. Total volume equals area x total weld length; mm2 x m converts to cm3 by dividing by 1,000.
The fill factor multiplies the theoretical volume and weight. Use it only for a defined allowance, not process efficiency. This calculator estimates deposited metal geometry; consumable ordering also needs process efficiency, stub loss and waste.