Welding Calculator
Calculate heat input, filler metal needs, gas consumption. MIG, TIG, Stick, Flux-core.
📋 Quick Examples — Click to Load
Planning estimates only. Verify with a licensed engineer or contractor before construction.
📐 Construction Industry Facts
Heat Input = (V×A×60)/(S×1000) kJ/in
— AWS
Fillet area = size²/2
— Geometry
Heat input = (V × A × 60) / (Travel Speed × 1000) kJ/in. Filler = volume × density × passes / efficiency. MIG 95%; TIG 99%; Stick 60%; Flux-core 85%. Gas flow 20–35 CFH typical. Match filler to base metal.
Sources: AWS standards, Lincoln Electric, Miller, ESAB.
Key Takeaways
- • Heat Input = (V × A × 60) / (Travel Speed × 1000) kJ/in
- • Filler = Weld volume × density × passes / efficiency
- • MIG 95%; TIG 99%; Stick 60%; Flux-core 85% efficiency
- • Gas consumption = Flow × Weld time × passes
Did You Know?
How Does It Work?
Heat Input
HI = (V×A×60)/(S×1000). V=voltage, A=amperage, S=travel speed IPM.
Fillet Weld
Area = size²/2. Filler = volume × density × passes / efficiency.
Gas
Gas = flow rate × weld time. 20–35 CFH typical for MIG/TIG.
Expert Tips
Process Comparison
| Process | Efficiency | Gas |
|---|---|---|
| MIG (GMAW) | 95% | Yes |
| TIG (GTAW) | 99% | Yes |
| Stick (SMAW) | 60% | No |
| Flux-Cored (FCAW) | 85% | No |
Frequently Asked Questions
What is heat input in welding?
Heat input = (V × A × 60) / (Travel Speed × 1000) kJ/in. Controls weld penetration and HAZ. Typical range 0.5–2.5 kJ/in for steel. Too high can cause grain growth; too low can cause lack of fusion.
How do I calculate filler metal needed?
Filler = (Weld volume × density × passes) / efficiency. Fillet weld area = size²/2. MIG 95% efficiency; TIG 99%; Stick 60%; Flux-core 85%. Volume in cubic inches × density lb/in³.
What gas flow rate for MIG welding?
Typical 20–35 CFH for MIG/TIG. C25 (75/25 Ar/CO2) most common for steel. Pure argon for aluminum. Too low = porosity; too high = turbulence and waste.
MIG vs TIG vs Stick welding?
MIG: fast, easy, 95% efficiency; needs gas. TIG: precise, clean, 99% efficiency; slower. Stick: portable, no gas, 60% efficiency; works outdoors. Flux-core: high deposition, no gas outdoors.
How does travel speed affect the weld?
Travel speed is critical for heat input. Faster = less heat input, less penetration. Slower = more heat, deeper penetration. Formula: HI = (V×A×60)/(S×1000). S = travel speed IPM.
What filler for mild steel?
ER70S-6 for MIG; E7018 for stick. Match filler to base metal. ER308L for stainless 304; ER4043 for aluminum. Check AWS classification.
Key Statistics
Official Data Sources
⚠️ Disclaimer: This calculator is for educational purposes only. Verify with WPS and qualified welder. Safety first.
Related Calculators
Carbon Equivalent Calculator - Weldability Analysis
Calculate carbon equivalent (CE) values for steel to assess weldability and cracking susceptibility. Get CE formulas, material analysis, and welding...
ConstructionK-Factor Calculator - Sheet Metal Bending Calculator
Calculate K-factor for sheet metal bending operations. Get bend allowance, bend deduction, and flat pattern development for various materials and thicknesses.
ConstructionMaterial Removal Rate Calculator - Machining Calculator
Calculate material removal rate (MRR) for milling, turning, and drilling operations. Get cutting parameters, feed rates, and machining efficiency...
ConstructionPunch Force Calculator - Press Brake & Punching Calculator
Calculate punch force requirements for press brake operations and hole punching. Get tonnage requirements, material thickness limits, and press...
ConstructionSpindle Speed Calculator - RPM & Cutting Speed Calculator
Calculate spindle speed (RPM) and cutting speed for milling, turning, and drilling operations. Get optimal speeds, feed rates, and machining parameters.
ConstructionAir Changes Per Hour Calculator - Ventilation & HVAC Design
Calculate air changes per hour for proper ventilation and HVAC design. Determine if your room meets recommended ACH standards for different room types...
Construction