Handbook - Calculations

Covered
Electrodes

Stainless
Steel Electrode or Welding Wire Consumption
Products

Pounds/Foot (Kilos/meter) of Electrode or Wire

Fillet Size Weld Metal
Solid Wire Required
Required per Lineal Foot or (Meter) of Weld
& Rod
Horizontal in. (mm)
SMAW-Stick GMAW-Solid FCAW-Gas Metal Cored
L lbs/ft (kg/m)
Fillet Electrodes Wires Shielded Wires
Products 1/8 (3.2) .027 (.040) .043 (.064) .028 (.042) .032 (.048) .029 (.043)
Welds
3/16 (4.7) .060 (.089) .097 (.144) .063 (.094) .070 (.104) .065 (.097)
1/4 (6.3) .106 (.158) .171 (.254) .112 (.167) .125 (.186) .115 (.171)
ESAB
5/16 (7.9) .166 (.247) .268 (.399) .175 (.260) .195 (.290) .180 (.268)
TIG & MIG L
3/8 (9.5) .239 (.356) .385 (.573) .252 (.375) .282 (.420) .260 (.387)
Wires
1/2    (12.7) .425 (.632) .686   (1.020) .447 (.665) .50 (.744) .462 (.688)
L
5/8    (15.8) .664 (.988)   1.071   (1.594) .699   (1.040) .781   (1.162) .722  (1.074)
Cored 3/4    (19.1) .956   (1.423)   1.542   (2.295)     1.010 (1.503) 1.125 (1.674) 1.039  (1.546)
Wire 1    (25.4) 1.698 (2.527)  2.739 (4.076) 1.787 (2.659)   2.0   (2.976)  1.846  (2.747)
Products

Submerged
Arc Electrode Consumption (cont’d.)
Products
Square
Hard- Butt Weld Metal Stick Electrodes
surfacing Joint Dimensions - Inches (m m ) Required Required
Filler Metal
Joint T B A lbs/ft (kg/m ) lbs/ft (kg/m )
Products Consumption
3/16    (4.7) 1/16 (1.6) 3/8    (9.5) .093 (.138) .150 (.223)
StubLoss
Correction A 1/16 (1.6) .115 (.171) .185 (.275)
Calculations 1/16"
1/4    (6.3) 7/16   (11.1)
Electrode/Wire 3/32 (2.4) .142 (.211) .229 (.341)
Consumption
1/16 (1.6) .137 (.204) .220 (.327)
T 5/16    (7.9) 1/2   (12.7)
Weld Metal Cost
Filler Metals Worksheet 3/32 (2.4) .165 (.245) .266 (.396)
ASTM B
Weight/Foot
Steels Weld Metal

Weight/Meter
Conversion Weld Metal
Tables 4

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