Deposition Estimator
Calculate the actual weight of filler metal deposited into a joint per hour, factoring in the efficiency loss from spatter, slag, and fumes.
Hourly Rates (100% Arc-On Time)
Net Weld Deposited
Deposition Rate & Efficiency Calculator
Actually enters the joint
Spatter & Slag Loss
--
lbs/hrLost to waste
Total Wire Melted (Purchased):
0.0 lbs/hr
The Cost of Efficiency
A higher gross melt-off rate doesn't always equal a faster weld. If you use a low-efficiency process, you are paying for wire that ends up as floor sweepings.
Typical Process Efficiencies
| Process | Avg. Efficiency | Primary Loss |
|---|---|---|
| SAW (Sub-Arc) | 99% | Negligible |
| GMAW (Solid Wire) | 95 - 98% | Spatter / Fume |
| MCAW (Metal-Core) | 90 - 95% | Spatter / Fume |
| FCAW (Flux-Core) | 80 - 85% | Slag / Fume |
| SMAW (Stick) | 55 - 65% | Slag / Stubs |
Purchasing Impact
To deposit 100 lbs of weld metal using Flux-Core (82% eff), you must purchase and melt 122 lbs of wire. Using Solid MIG (95% eff), you only need to purchase 105 lbs.
Note: These figures assume 100% "Arc-On" time. To find actual shift production, multiply the Net Deposition by your operator's Operating Factor (typically 20% to 40%).