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Welding consumables calculator

Enter the total seam length, the fillet leg size and the consumption parameters. The calculator estimates the deposited metal mass and how much wire or electrode to buy, losses included.

Approximate formula for a fillet weld: cross-section ≈ 0.5 × leg²
Share of the wire's metal that actually lands in the weld — usually 85–95% for MIG/MAG

Result

Wire/electrode needed

—

Deposited metal mass —
Consumables cost —

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This calculation is for informational purposes only and does not replace advice from a qualified professional. Formulas and rates may not fit your exact situation — double-check the figures before making decisions.

How it is calculated

Fillet weld cross-section is approximated as 0.5 × leg² — a standard shortcut used for consumption estimates; the exact figure depends on the weld's shape and penetration. Deposited metal mass = cross-section × total seam length × weld metal density.

Actual wire consumption is higher than the deposited metal mass: some of it is lost to spatter, stub ends and feed losses. Required mass = deposited metal mass ÷ (deposition efficiency ÷ 100) × (1 + extra loss ÷ 100).

This gives an estimate for planning a purchase, not an exact consumption norm for a specific process — refine it against your own equipment and consumables after the first batches.

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