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Formulas
Formulas
Formulas
E.g.: Wire diameter = 0.045 in. (1.2 mm) solid wire, WFS = 300 IPM.
Deposition rate = 13.1×(0.045)2 ×(300)×(1.0) = 7.96 lb./hr
Calculating travel speed with deposition rate — Knowing the deposition rate, we can calculate
the travel speed in inches per minute (IPM) for a particular weld. Let's say we want to make a 3/8-in.
steel fillet weld (assume 10% reinforcement or 0.4125 in. leg) using 0.045-in. solid wire at 300 IPM,
the weight of weld metal per foot can be calculated by multiplying the density of steel (0.283 lb./in 3)
by the volume of weld metal per foot as follows:
Weld weight per foot calculation
Vol. of weld metal/ft=1/2×b×h×12 in.=1/2×0.4125 in.×0.4125 in.×12 in.=1.02 in 3.
Weight of weld metal/ft of 3/8 in. fillet weld=(0.283 lb./in 3)×(1.02 in3)=0.2887 lb./ft.
From the calculation below, we see that the travel speed for a one-pass, 3/8-in. fillet weld would be
5.52 IPM, 11.03 IPM for a two-pass fillet weld, or 16.55 IPM for a three-pass weld.
Travel speed calculation
Travel speed = (deposition rate)×(# of passes)/5×(weight of weld metal per foot {lb./ft}) = (7.96)×(1)/5
× (0.2887) = 5.52 IPM
Calculating wire-feed speed with deposition rate — Let's assume a requirement to make fillet
welds at a rate of 12 lb./hr using 0.045 in. welding wire. We can calculate the WFS using the
formulas below and Weight of Weld Wire per foot in Table 1.
Wire-feed speed calculation
Wire-feed Speed = (deposition rate)/5×(weight of wire per foot {lb./ft}) = (12)/5×(0.0054) = 444.4 IPM