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Weld Volume/Filler Metal Weight Calculator: Magnatech Pipe Welding Systems
Weld Volume/Filler Metal Weight Calculator: Magnatech Pipe Welding Systems
The purpose of this program is to allow quick calculation of arc times, weld times, and filler metal
requirements for manual, semiautomatic, and mechanized pipe welding projects. Four of the most
common pipe joint preparations can be used in the calculations.
A guide to approximate deposition rates for different processes is given. Attention: these are for
welding pipe in the fixed position only and are not representative of higher rates achievable when
the pipe can be rolled. Although deposition rates and duty cycles have been taken from a wide
range of industry sources, they are to be used a guidelines only. Individual applications, welder
skills, and whether the welding is to be done in a fabrication facility or during field erection can
make these assumptions inaccurate. We encourage each user to check the standard assumptions
against actual company productivity data and use this actual data for any calculations. Certain
applications, for example welding materials requiring strict control of interpass temperature,
markedly affect the duty cycle, whether the welding is done manually or with mechanized
equipment. We encourage you to check calculated times for future projects against actual welding
rates achieved.
This Calculator allows a quick comparison between manual and mechanized techniques and
provides realistic information on the productivity improvements that can be achieved using
mechanized welding. However, it should be used as a guide only. Given the many workplace
variables, Magnatech can assume no liability or responsibility for the accuracy of this Calculator to
predict actual arc times and weld times for all circumstances.
A. GENERAL
All assumptions based on welding in fixed 5G position. The torch must be moved around stationary
pipe.
B. DEFINITIONS
1. Deposition Rate - Weld Metal Deposited Assuming 100% "Arc On"/Duty Cycle Time
>Manual or Mechanized Orbital GTAW - 1lb/hr (0.45 kg/hr)
>Manual SMAW - 6 lbs/hr (2.27 kg/hr)
>Semiautomatic GMAW/FCAW - 8 lbs/hr (3.6 kg/hr)
>Mechanized Orbital GMAW/FCAW - 8 lbs/hr (3.6 kg/hr)
3. Arc Time
>Time to weld the joint assuming 100% duty cycle
4. Weld Time
>Time to weld the joint assuming realistic duty cycle.
Magnatech Pipe Welding Systems
Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
TYPICAL JOINT DETAILS
1. GENERAL
Typical ranges of dimensions are given below as a guide only - use specific dimensions, if
available.
2. TYPICAL DIMENSIONS
V = Bevel:
A = Bevel Angle: 37.5° (ASME) or 30° (API)
L = Land Thickness: 0.062 - 0.125" (1.5 - 3mm)
G = Gap: 0.062 - 0.125" (1.5 - 3mm)
C = Cap Height 0.125" (3mm)
Compound V-Bevel:
A1 = Primary Bevel Angle: 37.5° (Angle closest to ID)
A2 = Secondary Bevel Angle: 10% (Angle closest to OD)
L = Land Thickness: 0.062 - 0.125" (1.5 - 3mm)
G = Gap: 0.062 - 0.125" (1.5 - 3mm)
H = Dimension to A2: 0.75" (19mm) (Dimension from pipe ID at which bevel angle changes)
C = Cap Height: 0.125" (3mm)
J-Bevel:
A = Bevel Angle: 20°
L = Land Thickness: 0.050" - 0.062" (1.3 - 1.5mm)
E = Land Extension: 0.030 - .050" (.75 - 1.3mm)
C = Cap Height: 0.125" (3mm)
R = Radius: 0.094" (2.4mm)
Compound J-Bevel:
A1 = Primary Bevel Angle: 37.5° (Angle closest to ID)
A2 = Secondary Bevel Angle: 10% (Angle closest to OD)
L = Land Thickness: 0.050 - 0.062" (.75 - 1.5mm)
E = Land Extension: 0.030 - 0.050" (.75 - 1.3mm)
H = Dimension to A2: 0.75" (19mm)(Dimension from pipe ID at which bevel angle changes)
C = Cap Height: 0.125" (3mm)
R = Radius: 0.094" (2.4mm)
Magnatech Pipe Welding Systems
Weld Volume/Filler Metal Weight Calculator Copyright Magnatech 2001
Joint Details Production Details