• Post category:weld tech

Consumables consumption in welding operations

Consumables consumption in welding operations

Calculating the consumption of consumables in welding operations is an essential step to estimate the cost of the project. The category of consumables includes electrodes, filler wires, shielding gases, flux, etc.

We can calculate consumable consumption with the following formula:

Consumables consumption in welding operations

Where w =weight of consumable(grams)                    

A=Cross sectional area (Cm)2

ρ= Density (gr/cm3)  

  L= Length (cm)   

  E= Deposition efficiency

  •                                                    

Cross-sectional area

Consumables consumption in welding operations
Consumables consumption in welding operations

Where A =Cross sectional area, r=root gap,t=thickness of the base metal,f =root face, and θ= Included angle

Density 𝜌

The table of densities of the most common materials is as follows

Densities of Common materials

Material Density (g/cm)3
Carbon steel 7.8
Magnesium 1.7
Granite 2.6-2.7
Diamond 3.5
Steel 7.8
Iron 7.8
Brass 8.6
Copper 8.3-9.0
Lead 11.3
Mercury 13.6
Uranium 18.7
Gold 19.3
Platinum 21.4
Iridium 22.4

density can be changed by changing either the pressure or the temperature. Increasing the pressure always increases the density of a material. Increasing the temperature generally decreases the density, but there are notable exceptions to this generalization

Changes of density

Deposition efficiency “E”

Welding processTypical Deposition Efficiency range(%)Approx
Shielded metal arc welding SMAW50-55
Gas tungsten arc welding GTAW92-96
Submerged arc welding SAW96-98
Self-shielded Flux-cored arc welding FCAW-S72-78
Gas shielded arc welding FCAW-G80-88
Gas metal arc welding GMAW96-98