Weld Metal Weight Calculator
Find how many pounds of weld metal a joint takes and how much rod or wire to buy.
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Lb. Filler to Buy
- Weld area
- Weld metal per foot
- Weld metal deposited
- Filler needed
- Metric
- Filler Cost
Weld List
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| Joint | Size | Ft. | Deposited Lb. | Buy Lb. | Remove |
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How to Calculate Weld Metal Weight
Find the cross-section area of the weld, multiply by its length for volume, and multiply by the density of steel (0.2836 lb per cubic inch). Then divide by the deposition efficiency to find how much filler metal to buy, since some of it ends up as stubs, spatter and slag.
Fillet: area = leg₁ × leg₂ ÷ 2
Single-V groove: area = gap × t + t² × tan(angle ÷ 2) Double-V: gap × t + t²/2 × tan(angle ÷ 2)
Weld metal (lb/ft) = area × 12 × 0.2836 × (1 + reinforcement) Filler to buy = weld metal ÷ efficiency
Worked Example
Fillet Weld Metal per Foot (No Reinforcement)
| Leg | Area (Sq. In.) | Lb. per Ft. |
|---|
Tips
Fillet weld volume goes up with the square of the leg: a ⅜″ fillet takes 2.25 times the metal of a ¼″. Oversized welds are the most common way welding cost creeps up. Deposition efficiencies above are typical figures; check the filler maker's data for your wire or rod.