How to Calculate Welding Rod Consumption
The amount of filler metal depends on the cross-sectional area of the weld joint, the length of the weld, and the deposition efficiency of the welding process.
Weld Volume = Cross-Section Area x Weld Length
Deposited Metal Weight = Volume x Density (7.85 g/cm³ for steel)
Filler Metal Required = Deposited Weight / Deposition Efficiency
Deposition Efficiency by Process
- SMAW (Stick): 55-70% - stub loss and spatter reduce efficiency
- GMAW (MIG): 90-97% - minimal waste with continuous wire feed
- GTAW (TIG): 95-100% - very precise with minimal waste
- FCAW (Flux-Core): 80-90% - flux adds to weight but reduces usable metal