Welding rod consumption
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How does everyone calculate the amount of welding rod needed? Those with welding experience, please share your knowledge!
There is a fixed consumption amount, which can be checked and calculated; it is generally twice the total volume of metal
We calculate it by taking twice the volume weight of the weld bead per electrode； The welding wire amount is calculated based on the weight of the weld volume.
Volume of weld * density of steel / coefficient; different welding methods have different coefficients – 0.55 for electrodes and 0.9–0.95 for wire
1. The consumption of welding rod is usually calculated using the following formula: Where: m = consumption of welding rod in grams; A = cross-sectional area of the weld in cm2, which can be calculated using the formula in Table 1-2; L = length of the weld in cm; P = density of the deposited metal in g/cm3; Ks = welding rod loss coefficient, as shown in Table 1-1. Welding rod loss coefficient Ks Table 1-1 Welding rod types (grades): E4303 (J422), E4320 (J424), E5014 (J502Fe), E5015 (J507). Ks values: 0.465, 0.47, 0.41, 0.44 respectively.
2. The consumption of non-ferrous powder-type welding rods can also be calculated using the following formula: Where: m = consumption of welding rod in grams; A = cross-sectional area of the weld in cm2, which can be calculated using the formula in Table 1-2; L = length of the weld in cm; P = density of the deposited metal in g/cm3; Kb = coating mass coefficient, as shown in Table 1-3; Kn = conversion efficiency of metal from the welding rod to the weld (including losses due to burning, spatter, and the welding rod tip), as shown in Table 1-4. Coating mass coefficient Kb Table 1-3 Welding rod types (grades): E4301 (J423), E4303 (J422), E4320 (J424), E4316 (J426), E5016 (J506), E5015 (J507). Kb values: 0.325, 0.45, 0.46, 0.32, 0.32, 0.41 respectively. Conversion efficiency Kn Table 1-4 Welding rod types (grades): E4303 (J422), E4320 (J424), E5014 (J502Fe), E5015 (J507). Kn values: 0.77, 0.7, 0.77, 0.79 respectively
2. The consumption of non-ferrous powder-type welding rods can also be calculated using the following formula: Where: m = consumption of welding rod in grams; A = cross-sectional area of the weld in cm2, which can be calculated using the formula in Table 1-2; L = length of the weld in cm; P = density of the deposited metal in g/cm3; Kb = coating mass coefficient, as shown in Table 1-3; Kn = conversion efficiency of metal from the welding rod to the weld (including losses due to burning, spatter, and the welding rod tip), as shown in Table 1-4. Coating mass coefficient Kb Table 1-3 Welding rod types (grades): E4301 (J423), E4303 (J422), E4320 (J424), E4316 (J426), E5016 (J506), E5015 (J507). Kb values: 0.325, 0.45, 0.46, 0.32, 0.32, 0.41 respectively. Conversion efficiency Kn Table 1-4 Welding rod types (grades): E4303 (J422), E4320 (J424), E5014 (J502Fe), E5015 (J507). Kn values: 0.77, 0.7, 0.77, 0.79 respectively
Based on simple calculations, the utilization rate is 0.5 for 1 kilogram of carbon steel welding rods and 0.48 for stainless steel welding rods. The amount of filler metal in the actual weld can then be calculated.