Wire Usage Information

The first section is from Lincoln Electric: GMAW Welding Guide

To determine the deposition rate for a given diameter of solid carbon or low alloy steel wire electrode the following mathematical formula will be useful:

13.1 (D2)(WFS)(EE)

where: D = electrode diameter
WFS = wire feed speed (inches per minute)
EE = electrode efficiency
13.1 = is a constant that is based upon the density of steel and its cross-sectional area.

If the melt off rate is all that is required, then use the same formula and remove the factor for EE.

Aluminum is approximately 33% the density of carbon steel, and its constant will be 13.1 x .33, or 4.32. Stainless steel, typically, is only slightly greater in density than carbon steel, 0.284 lbs/in3 versus 0.283 lbs/in.3, and therefore the 13.1 constant is sufficient.

WIRE DEPOSITION RATE

(Useful when calculating anticipated wire usage)

English: Calculate by multiplying the following:
• For .030 in. wire- multiply the wire feed speed in in./min by .0123
• For .035 in. wire- multiply the wire feed speed in in./min by .0167
• For .045 in wire- multiply the wire feed speed in in./min by .0277

Example: Wirefeed rate= 320 in./min; wire size= .030 in. Deposition rate= 320 x .0123 = 3.94 lb./hr

Metric: Calculate by multiplying the following:
• For .8mm wire- multiply the wire feed speed in mm/min by .00022
• For .9mm wire- multiply the wire feed speed in mm/min by .00033
• For 1.2mm wire- multiply the wire feed speed in mm/min by .00050

Example: Wirefeed rate= 7400mm/min; wire size= .8mm Deposition rate= 7400 x .00022 = 1.63 kg/hr.