Wire Feed Speed for a Target Deposition Rate
The wire feed speed a target deposition rate needs.
Example
You enter
- Target deposition rate (lb/hr) 6
- Wire diameter (in) 0.035
- Deposition efficiency (0-1) 0.92
You get
- Required wire feed speed 398 in/min
- Melt-off rate 6.52 lb/hr
No published worked example is on file for this calculation. It is checked against a hand-worked derivation of its method and an independent reference test.
Details, formula, and sources
ScopeWFS = deposit / (60 x wire cross-section x 0.2836 x efficiency). A 6 lb/hr target on 0.035 in wire at 92% efficiency needs about 398 in/min; a smaller wire needs a much higher speed (rate goes as diameter squared). Answers 'what WFS to set' instead of the rate from a set speed. The WFS must be within the WPS-qualified range; the WPS and process govern.
Formula or tableWire cross-section = pi/4 x diameter2; wire feed speed (in/min) = target_deposit (lb/hr) / (60 x area x 0.2836 lb/in3 x efficiency); melt-off = deposit / efficiency. The inverse of deposit = WFS x 60 x area x density x efficiency.
Source and editionWire feed speed for a target deposition rate - first-principles wire-volume geometry and steel density (0.2836 lb/in3), by name, solved for the feed speed; public domain.
Free accessPure volume-rate geometry, public; the target deposition rate, diameter, and deposition efficiency are user-supplied.
What governsEstimate. AHJ and licensed professional govern.
API field namestarget_deposit_lb_hr, wire_dia_in, deposition_eff, wfs_in_min, melt_lb_hr
- Steel density 0.2836 lb/in3 (carbon steel), fixedfirst-principles
- Deposition efficiency deposited / melted; default 0.92 solid wireWPS / process