Process affects deposition rate, consumable type and labour estimate.
Fillet welds, butt welds and groove welds require different weld metal volumes.
Weld Dimensions
Enter total length of weld, including all seams, joints or passes you want to estimate.
Allow extra for starts/stops, restarts, setup, grinding, rejected welds and site conditions.
Enter your weld details
Select your welding process, joint type, and dimensions to estimate the required rods, wire, gas, and prep consumables.
Welding Process Guide
Choosing the right welding process impacts the speed, quality, and consumable usage of your project. Here are the 5 main processes explained in practical terms:
SMAW / Stick Welding
Uses coated consumable electrodes (like E6013 or E7018). Ideal for site work, maintenance, and structural welding because it is less sensitive to wind and dirty materials.
GMAW / MIG / CO2 Welding
Uses a continuous solid wire and external shielding gas. Highly efficient and fast, making it the standard for workshop fabrication and thinner materials.
FCAW / Flux Core Welding
Uses a tubular wire filled with flux. Can be gas-shielded or self-shielded. Excellent for heavier fabrication, outdoor work, and high deposition rates.
GTAW / TIG Welding
Uses a non-consumable tungsten electrode and a separate filler rod. Produces high-quality, precise welds. Commonly used for stainless steel, aluminium, and pipe roots.
SAW / Submerged Arc Welding
An automated process where the arc is submerged under a blanket of granular flux. Used for heavy fabrication, long continuous seams, and high-volume production welding.
Welding Positions Explained (1G to 6G)
Welding positions are coded using a number and a letter. The number indicates the position (1 to 6), and the letter indicates the weld type (F for Fillet, G for Groove/Butt).
Practical Note: Position affects welding speed, difficulty, consumable usage, grinding/cleaning time and labour estimate. Overhead, vertical and fixed pipe positions usually take more time than flat welding.
This is educational guidance only. Qualification and procedure requirements depend on welding code, material, joint type and project specification.
Electrode Codes Explained
SMAW (Stick) electrodes use a standard coding system to indicate their properties. Let's break down the common E6013 and E7018 electrodes:
- E = Electrode
- First two digits = Tensile strength (e.g., 60 = ~60,000 psi, 70 = ~70,000 psi)
- Third digit = Position suitability (1 = all-position, 2 = flat/horizontal only)
- Last digit = Coating type and welding current characteristics
E6013 Example
A general-purpose rutile electrode. Excellent for light fabrication, sheet metal, and general maintenance. It provides a smooth arc, light spatter, and easy slag removal.
E7018 Example
LH electrodes usually refer to low-hydrogen types such as E7018. Used for stronger structural welds and critical work. Requires proper storage (often in an oven) to avoid moisture contamination.
Brand names such as Vitamax may vary by supplier. Always check packet, welding procedure or data sheet for exact classification.
Common Electrode & Consumable Types
| Consumable | Common Use | Notes |
|---|---|---|
| E6013 electrode | Light fabrication, sheet metal, maintenance | Rutile type, smooth arc, easy slag removal |
| E7018 low-hydrogen electrode | Structural welds, critical work | Requires proper storage, low hydrogen control |
| MIG solid wire | Workshop fabrication, thinner materials | Continuous wire, requires shielding gas |
| Flux core wire | Heavier fabrication, higher deposition | Gas-shielded or self-shielded options |
| TIG filler rod | Stainless steel, aluminium, high-quality welds | Separate filler, requires tungsten electrode |
| CO2 shielding gas | MIG welding | Standard shielding gas |
| Argon / mixed gas | TIG welding, stainless MIG | Premium shielding gas |
| Grinding discs | Weld prep, cleanup, finishing | Consumable item |
| Cutting discs | Material prep | Consumable item |
| Flap discs | Weld finishing, blending | Consumable item |
| Anti-spatter | Prevents spatter adhesion | Spray or paste application |
| Whitewash / lime wash | Low-cost anti-spatter barrier on large jobs | Workshop method, test before use, do not use where coating/paint/stainless/procedure does not allow |
What Affects Welding Time and Consumable Use
Estimating welding is rarely an exact science. Several variables will impact how much material and time a job actually takes:
Practical Note: Flat workshop welding is normally faster than overhead, vertical or fixed pipe welding. Use calculator result as estimate and adjust for real job conditions.
Frequently Asked Questions
Important Disclaimer
Related Calculators
Calculation method, worked example and reference
What this calculator does and formula: Deposited weld mass = weld cross-sectional area × length × metal density. Required consumable divides deposited mass by process deposition efficiency and adds waste where selected.
Variables and units: Enter values in the units named by the controls. The calculator converts through its internal base unit or applies the displayed geometric or financial relationship before rounding the presented result.
Verified worked example: A deposited weld volume of 100 cm³ at 7.85 g/cm³ contains 0.785 kg of weld metal before efficiency loss.
Result interpretation, assumptions and practical limits: Joint geometry, root gap, reinforcement, process efficiency and procedure qualification change consumption. Welding must follow the approved WPS and safety controls.
Professional check: Treat the result as a planning estimate. Where safety, regulated work, contracts or significant money are involved, verify inputs and the result with the governing standard, manufacturer data and an appropriately qualified professional.