Wire Feed Speed to Deposition Rate
Melt-off rate from wire feed speed and electrode diameter, and the deposition rate after spatter loss, from first-principles wire-volume geometry and steel density. Pairs with weld-metal-volume for arc time. The WPS and process (spray vs short-circuit, gas) govern the real efficiency.
Formula and source
Wire cross-section = pi/4 x diameter2; melt-off rate (lb/hr) = wire feed speed (in/min) x 60 x area x 0.2836 lb/in3; deposition rate = melt-off x deposition efficiency.
Melt-off and deposition rate from wire feed speed - first-principles wire-volume geometry and steel density (0.2836 lb/in3), by name; public domain.
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