How do you calculate filler rod usage?

Answer 1

HOW TO CALCULATE THE CONSUMPTION OF FILLER METAL

The following tables will help you estimate electrode quantity and cost for a variety of joints. The bases for the tabulations are explained below. Should you encounter a variation in conditions or joint preparation that is not shown in the tables, substitute appropriate figures in the W =D formula and calculate it. Electrode requirements have been calculated as follows: 1-L

W =D

1-L W=Weight of electrodes required

D=Weight of steel deposited

L=Total electrode losses

To arrive at the weight of steel deposited, it is necessary to calculate first the volume of deposited metal (area of the groove multiplied by the length). Then this volumetric value is converted to weight by the factor 0.283 pounds per cubic inch for steel. Where weld reinforcement is involved, it is added to the requirements for net, unreinforced welds. These figures are based on the efficiency of the process used. On square and "V" groove joints, the figures are based on stick electrode efficiency. For tubular wire results, divide steel deposit weight by .80 and for solid wire divide by .90.

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E

E

F

I

G

U

R

E

1

Size of fillet

L

(in inches)

Steel deposited

per linear foot

of weld (lbs.)

Pounds of electrodes required

per linear foot of weld* (approx.)Stick*TubularSolid

• 1/8
• 3/16
• 1/4
• 5/16
• 3/8
• 1/2
• 5/8
• 3/4
• 1

• 0.027
• 0.063
• 0.106
• 0.166
• 0.239
• 0.425
• 0.663
• 0.955
• 1.698

• .049
• .114
• .193
• .302
• .434
• .773
• 1.205
• 1.736
• 3.087

• .034
• .079
• .133
• .208
• .298
• .531
• .829
• 1.194
• 2.123

• .03
• .07
• .118
• .184
• .265
• .472
• .737
• 1.061
• 1.890

*Includes scrap end and spatter loss

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2Joint dimensions (in inches)Steel deposited per linear foot of weldPounds of electrodes required per linear foot of weld* (approx.)

MTL. THICK TBEAD WIDTH BROOT OPEN GWithout rein- forcement(lbs.)With rein- forcement(lbs.)Without reinforcementWith reinforcement**

3/16

1/4

5/163/8

7/16

1/2

• 0
• 1/16
• 1/16
• 3/32
• 1/16
• 3/32

------ 0.020

0.027

0.039

0.033

0.0500.088

0.109

0.129

0.143

0.153

0.170------ 0.04

0.05

0.07

0.06

0.090.16

0.20

0.23

0.26

0.27

0.301/8

3/16

1/41/4

3/8

7/16

• 0
• 1/32
• 1/32
• 1/16
• 1/16
• 3/32

------ 0.013

0.020

0.040

0.053

0.0800.119

0.132

0.199

0.218

0.261

0.288------ 0.03

0.04

0.07

0.10

0.140.21

0.24

0.36

0.39

0.47

0.53

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3

Joint Dimensions (in inches)

Steel deposited per linear foot of weldPounds of electrodes required per linear foot of weld* (approx.)

MTL. THICK

T

BREAD WIDTH

B

ROOT OPEN

G

Without rein- forcement(lbs.)

With rein- forcements**(lbs.)Without rein- forcementWith rein- forcement**1/4

5/16

3/8

1/2

5/8

3/4

10.207

0.311

0.414

0.558

0.702

0.847

1.1381/16

3/32

1/8

1/8

1/8

1/8

1/80.085

0.173

0.282

0.489

0.753

1.088

1.9300.143

0.258

0.394

0.641

0.942

1.320

2.240

• 0.15
• 0.31
• 0.50
• 0.87
• 1.35
• 1.94
• 3.45

• 0.25
• 0.46
• 0.70
• 1.15
• 1.68
• 2.35
• 4.00

*Includes scrap end and spatter loss. **R=Height of reinforcement.

Figure 1 Figure 2