Welding Calculator

Comparison of welding economy
for fillet welds

MEGAFIL 710 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
labour and overhead costs
amperage
deposition rate
welding duty cycle
price of welding consumable
weld metal recovery
price of gas
gas volumetric flow rate
gas consumption = 60 x GS /Ax ED
gas costs = Gp x Gv
welding costs = Zp / E x 100
production costs = L / A x ED
1.2
55
380
6.6
40
5
96
0.002
12
272.73
0.55
5.21
20.83
26.59
total costs = Fk + Zk + Gk
weld-reina-dimension
forcement
[mm]
[ mm ]
14
weight of weld
[kg/m]
90
1.832
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
SG2 massief
1.2
55
380
5.2
40
2
96
0.002
15
432.692
0.87
2.08
26.44
29.39
mm
/h
A
kg/h
%
/l
l/min
L/kgSG
/kgSG
rutile or basic flux-cored wire *
weld reinforcement
/kgSG
/kgSG
/kgSG
53.83
required wire quantity [ kg/mSN ]

solid or metal powder flux-cored wire*
production costs per meter fillet weld

[ / mSN ]
48.70
/kg
1.905
2.088
* for flux-cored wire with slag 86 % for solid and metal powder flux-cored wire 96 % recovery are considered
Remarks:

for U-butt welds
MEGAFIL 710 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas consumption = 60 x GS / Ax ED
gas costs = Gp x Gv
sheet thickness
s [mm]
weld preparation angle

gap width
b [mm]
root height
[mm]
radius
r
[mm]
weld reinforcement [mm]
20.0
8
1.0
3.0
8.0
width
[ mm ]
b2 [ mm ]
2.197
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
4
55
210
2.5
30
5
103
0.01
12
960
9.60
4.85
73.33
87.79
0.0
0.0
mm
/h
A
46.26
kg/h
%
/kg
%
b2
t
/l
l/min
b
L/kgSG
/kgSG
/kgSG
grooving out of cap pass
/kgSG
/kgSG
production costs per meter weld

[ / mSN ]
Remarks:
192.90

solid wire or metal powder flux-cored wire*
cap pass ( if necessary )
depth
weight of weld
[kg/m]
1.2
55
300
5.8
80
6.5
85
0.01
12
155.17
1.55
7.65
11.85
21.05
rutile oder basic flux-cored wire
2.3
2.5
* for flux-cored wire with slag 86 % and for folid or metal powder flux-cored wire 96 % recovery are considered

of V weld
MEGAFIL 710 M
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
sheet thickness
s [mm]

gap width b
[mm]
root height h
[mm]
depth
width
[ mm ]
b2 [ mm ]
25.0
60
3.0
1.0
2
1.0
1
weight of weld
[kg/m]
3.490
1.2
55
325
5.5
40
4
96
0.01
12
327.27
3.27
4.17
25.00
32.44
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
LMN 26
1.2
55
325
4.4
40
1.5
96
0.01
12
409.0909
4.09
1.56
31.25
36.90
mm
/h
kg/h
%
/kg
%
b2
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG

[ / mSN ]
113.23
Remarks:
d
128.81

solid or metal powder flux-cored wire *
3.63
3.98

for butt welds
MEGAFIL 235 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
wall thickness s
[mm]
gap width b
[mm]
~pass -depth L1
[mm]
~cap pass-depth L2 [mm]
weld reinforcement h1 [mm]
3.0
0.5
3.0
0.0
0.0
1.0
weight of weld
[kg/m]
0.012
1.2
55
300
5.8
80
6.5
85
0.01
12
155.17
1.55
7.65
11.85
21.05
mm
Euro/h
A
kg/h
%
Euro/kg
%
Euro/l
l/min
L/kgSG
Euro/kgSG
Euro/kgSG
Euro/kgSG
Euro/kgSG
1.2
55
300
5.8
80
4.5
85
0.01
12
155.1724
1.55
5.29
11.85
18.70
mm
Euro/h
A
kg/h
Euro/kg
%
l/min
L2
h2
Euro/kgSG
Euro/kgSG
Euro/kgSG
If the weld reinforcement shall be considered,

the desired, respecitvely suspected penetration depth L1 und L2
have to be indicated..
Euro/kgSG
0.22
L1
L/kgSG

Euro/l

[ / mSG ]
0.25
h1
0.012
0.013
Remarks:

for double-U butt weld
MEGAFIL 710 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
1.2
55
300
5.8
80
6.5
85
0.01
12
155.17
1.55
7.65
11.85
21.05
U-depth
s1
[mm]
gap width b
[mm]
weld preparation angle 1
U-depth
s2
[mm]
root height h1
[mm]
wall thickness s1+s2+h1[mm]

weld reinforcement 3h [mm]
6.0
2.0
2
2.0
2
3.0
1.0
1
1.0
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
4
55
210
2.5
30
5
103
0.01
12
960
9.60
4.85
73.33
87.79
mm
/h
0.72
0.034
h2
kg/h
%
b2
r1
/kg
%
/l
s1
r2
b
l/min
s2
L/kgSG
/kgSG
h3
/kgSG
/kgSG
/kgSG

[ / mSN ]
weight of weld
[kg/m]
Remarks:
3.01

depth
width
[ mm ]
b2 [ mm ]
radius r1 [ mm ]
radius r2 [ mm ]
1.0

0.036
0.039


for double-V butt welds
MEGAFIL 807 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
1.2
55
300
5.8
80
6.5
85
0.01
12
155.17
1.55
7.65
11.85
21.05
V-depth
s1
[mm]
gap width b
[mm]
V-depth
s2
[mm]
root height h1
[mm]

0.0
0.0
0
0.0
0
0.0
0.0
0
0.0
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
4
55
210
2.5
30
5
103
0.01
12
960
9.60
4.85
73.33
87.79
/h
A
0.00
0.000
h2
kg/h
%
b2
/kg
%
s1
/l
l/min
s2
L/kgSG
/kgSG
2
/kgSG
h3
/kgSG
/kgSG

[ / mSN ]
weight of weld
[kg/m]
mm
Remarks:
0.00

depth
[ mm ]
width
b2 [ mm ]
0.0
0.0

0.000
0.000

* for flux-cored wire with slag 86 % for solid and metal powder flux-cored wire 96 % recovery are considered.
This programme considers standard weld preparation with a simplified weld geometry. By entering variables into the dark blue field, the
welding costs per meter weld, as well as required wire quantity can be determined.

for single-bevel butt welds
MEGAFIL 710 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
sheet thickness s [mm]

gap width
b
[mm]
root height h
[mm]
depth
width
b2 [ mm ]
[ mm ]
1.0
0
3.0
0.0
0
2.0
3
weight of weld
[kg/m]
0.028
1.2
55
300
5.8
80
6.5
85
0.01
12
155.17
1.55
7.65
11.85
21.05
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
4
55
210
2.5
30
5
103
0.01
12
960
9.60
4.85
73.33
87.79
mm
/h
kg/h
%
/kg
%
b2
/l
l/min
b
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG

[ / mSN ]
0.60
Remarks:
2.48

0.0
0.0
* for flux-cored wire with slag 86 % for solid and metal powder flux-cored wire 96 % recovery are considered.

for double-bevel butt welds
MEGAFIL 742 M
L
I
A
ED
Zp
E
Gp
Gs
Gv
Gk
Zk
Fk
wire diameter
amperage
deposition rate
welding duty cycle
weld metal recovery
price of gas
gas costs = Gp x Gv
1.2
40
300
5.5
70
3
85
0.006
14
218.18
1.31
3.53
10.39
15.23
V-depth s1
[mm]
gap width b
[mm]
V-depth
s2
[mm]
root height h1
[mm]

2.0
0.0
0
0.0
1.0
0.0
0.0
1
0.0
mm
/h
A
kg/h
%
/kg
%
/l
l/min
L/kgSG
/kgSG
/kgSG
/kgSG
/kgSG
0.045
40
260
12.12
70
3
85
0.019
3.9
27.58
0.52
3.53
4.71
8.77
mm
0.00
0.000
h2
kg/h
%
b2
/kg
%
s1
/l
l/min
s2
L/kgSG
/kgSG
h3
/kgSG
2
/kgSG
/kgSG

[ / mSN ]
weight of weld
[kg/m]
/h
Remarks:
0.00

depth
[ mm ]
width
b2 [ mm ]
0.0
0.0

0.000
0.000


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Comparison of welding economy

for fillet welds

rutile or basic flux-cored wire *

required wire quantity [ kg/mSN ]

production costs per meter fillet weld

Comparison of welding economy

weld preparation angle

grooving out of cap pass

production costs per meter weld

required wire quantity [ kg/mSN ]

cap pass ( if necessary )

rutile oder basic flux-cored wire

Comparison of welding economy

weld preparation angle

grooving out of cap pass

production costs per meter weld

required wire quantity [ kg/mSN ]

Comparison of welding economy

rutile or basic flux-cored wire *

If the weld reinforcement shall be considered,

required wire quantity [ kg/mSN ]

production costs per meter weld

Comparison of welding economy

wall thickness s1+s2+h1[mm]

production costs per meter weld

grooving out of cap pass

cap pass ( if necessary )

required wire quantity [ kg/mSN ]

rutile or basic flux-cored wire *

Comparison of welding economy

wall thickness s1+s2+h1[mm]

production costs per meter weld

grooving out of cap pass

cap pass ( if necessary )

required wire quantity [ kg/mSN ]

rutile or basic flux-cored wire *

Comparison of welding economy

sheet thickness s [mm]

grooving out of cap pass

production costs per meter weld

required wire quantity [ kg/mSN ]

Comparison of welding economy

wall thickness s1+s2+h1[mm]

production costs per meter weld

grooving out of cap pass

cap pass ( if necessary )

required wire quantity [ kg/mSN ]

rutile or basic flux-cored wire *

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