Wire Feed Speed to Deposition Rate
Melt-off rate from wire feed speed and electrode diameter, and the deposition rate after spatter loss.
Example
You enter
- Wire feed speed (in/min) 300
- Wire diameter (in) 0.035
- Deposition efficiency (0-1) 0.92
You get
- Melt-off rate 4.91 lb/hr
- Deposition rate 4.52 lb/hr
Checked against published worked examples from: Welding Design & Fabrication (Penton Media).
Details, formula, and sources
ScopeFrom first-principles wire-volume geometry and steel density. Pairs with the weld metal volume for arc time. The WPS and process (spray vs short-circuit, gas) govern the real efficiency.
Formula or tableWire 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.
Source and editionMelt-off and deposition rate from wire feed speed - first-principles wire-volume geometry and steel density (0.2836 lb/in3), by name; public domain.
Free accessPure volume-rate geometry, public; the wire feed speed, diameter, and deposition efficiency are user-supplied.
What governsEstimate. AHJ and licensed professional govern.
API field nameswfs_in_min, wire_dia_in, deposition_eff, melt_lb_hr, deposit_lb_hr
- Steel density 0.2836 lb/in3 (carbon steel), fixedfirst-principles
- Deposition efficiency deposited / melted; default 0.92 solid wireWPS / process