DEPOSITION DATA

DEPOSITION DATA
DEPOSITION RATES, ELECTRODE EFFICIENCY, AND ELECTRODE WELD METAL RECOVERY! WHAT ARE THE DIFFERENCES?
Deposition Rates The deposition rate of a welding consumable (electrode, wire or rod) is the rate at which weld metal is deposited (melted) onto a metal surface. Deposition rate is expressed in kilograms per hour (kg/hr). Deposition rate is based on continuous operation, not allowing for stops and starts such as, electrode change overs, chipping slag, cleaning spatter, machine adjustments or other reasons. When welding current is increased so to does the deposition rate. When electrical stick out is increased in the case of GMAW and FCAW the deposition rate will also increase. Deposition rates are calculated by doing actual welding tests, and the following shows the formula for measuring deposition rates. Deposition Rate = Weight of test plate before welding - Weight of test plate after welding Measured period of time (normally 60 seconds). e.g. Plate before welding: 2kg - 2.95kg Plate after welding = 95grams, welded in 60 seconds. 95grams x 60/1000 = 5.7kg/hr.

ELECTRODE EFFICIENCY (DEPOSITION EFFICIENCY)

Technically to ISO 2401-1972 electrode efficiency (AS/NZS 1553.1: 1995 deposition efficiency) is the difference between the weight of the weld metal deposited and the weight of the filler metal consumed (not including flux and stub ends) in making the weld. The efficiency of an electrode is calculated by using the following formula; Electrode Efficiency % to ISO 2401and AS/NZS 1553.1 = Weight of test plate including weld metal - Weight of test plate before welding X 100 Mass of the Core Wire of 5 electrodes - Weight of core wire of the 5 stub ends

e.g. Satincraft 13 4mm x 380mm. Plate before welding: 2kg - 2.15kg Plate after welding = 150grams, weight of five (5) electrode core wires, 4mm x 380mm long before welding = 188grams, weight of five (5) electrode stub ends, 4mm x 50mm long after welding = 24.7grams, 150grams 163.3grams x 100 = 91.85% Electrode Efficiency (Deposition Efficiency).

e.g. Ferrocraft 22 3.2mm x 380mm. Plate before welding: 2kg - 2.167kg Plate after welding = 167grams, weight of five (5) electrode core wires, 3.2mm x 380mm long before welding = 124grams, weight of five (5) electrode stub ends, 3.2mm x 50mm long after welding = 16.3grams, 167grams 107.7grams x 100 = 155.06% Electrode Efficiency (Deposition Efficiency).

ELECTRODE WELD METAL RECOVERY (PROCESS EFFICIENCY)

Electrode weld metal recovery to ISO 2401-1972 allows us to calculate the amount of welding consumable which will actually be deposited into the finished weld metal less any waste such as, stub ends, slag and spatter not adhered to the test plate. An example is when 100kgs of electrodes are used with a quoted efficiency of 60%, the net result is that only 60kg of the weight of that electrode will actually end up in the deposited weld metal. The remaining 40% (40kg) of the electrode is waste. To achieve weld metal recovery rates practical tests are carried out by weighing the test plate before and after welding, weighing the consumables before welding and then using the following formula allowing for 50mm stub ends. If the welder discards more than 50mm stub ends than the recovery rate (process efficiency) will be lower. Weld Metal Recovery % to ISO 2401 =

e.g. Satincraft 13 4mm x 380mm. Plate before welding: 2kg - 2.15kg Plate after welding = 150grams, weight of five (5) electrodes, 4mm x 380mm long before welding = 261.20grams, 150grams 261.20grams x 100 = 57.43% Weld Metal Recovery (Process Efficiency).

e.g. Ferrocraft 22 3.2mm x 380mm. Plate before welding: 2kg - 2.167kg Plate after welding = 167grams, weight of five (5) electrodes, 3.2mm x 380mm long before welding = 281.50grams, 167grams 281.50grams x 100 = 59.33% Weld Metal Recovery (Process Efficiency).

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Weight of test plate before welding - Weight of test plate after welding X 100 Weight of the Consumable

DEPOSITION DATA
GENERAL PROCESS EFFICIENCIES
Welding Process Average Efficiency Gas Tungsten Arc Welding (GTAW) & Oxy-Acetylene Welding (OAW) 100% Manual Metal Arc Welding (MMAW) 60% Gas Metal Arc Welding (GMAW) Short Arc, Ar + 25% CO2 92% Gas Metal Arc Welding (GMAW) Spray Arc, Ar + 25% CO2 95% Gas Metal Arc Welding (GMAW) Pulse Arc, Ar + 25% CO2 98% Flux Cored Arc Welding (FCAW) E70T-4 types, self shielded 82% Flux Cored Arc Welding (FCAW) E71T-1 types, Ar + 25% CO2 85% Flux Cored Arc Welding (FCAW) E70T-5 types, Ar + 25% CO2 88% Flux Cored Arc Welding (FCAW) E70C-6M types, Ar + 25% CO2 92% Cobalarc Flux Cored Hardfacing Wires Gas shielded 80% GMAWandFCAWaverageefficienciescanvaryinresultdependingupontheshieldinggasesused,machinesettings,stickout,spatterlosses,wiresnipedoffbeforestartsetc.

CONSUMABLE WEIGHT CALCULATION

Required Welding Consumable In KG = (Area x 1 in M x 7900 KG) See detail below (Deposition efficiency as a percentage / 100) See detail above X Length In M

The Above formula will calculate your required weld metal using a particular welding consumable process in KG per Metre of weld. (Area x 1 in M x 7900 KG) Area can be calculated using the equations on page 560. By multiplying the area by 1 will give us a volume of weld metal required for every 1 metre of weld.We then multiply the volume by the weight of steel at 7900 KG per Cubic Metre to give us a weight in KG per Metre of weld. For ease of calculation we have included a series of tables on page 556 & 557. This can be used in the equation above in place of (Area x 1 in M x 7900 KG). The tables can be used as follows. Simply select the shapes from the above samples and read the relevant tables on the following page to determine the weight of weld metal in KG for every M of weld. Add each of the shapes together that make up your weld and insert in the equation above in place of (Area x 1 in M x 7900 KG). You can add 2 x Triangles together to get your total weld weight for a butt weld with 2 preps. In the Triangle table we have included the legth of the top of the weld so you can calculate the width of the Cap. (Deposition efficiency as a percentage / 100) See detail above Deposition efficiency is expressed as a percentage on this page above. Divide this percentage by 100 to convert to a decimal. W
TRIANGLE Weight of Weld Metal in KG/M of weld For Filet calculations use 45 degrees and F being the Fillet length X (Angle in degrees) 15 20 30 45 KG/M W KG/M W KG/M W KG/M 3.15 0.01 0.8 0.01 1.1 0.02 1.8 0.04 4.2 0.02 1.1 0.03 1.5 0.04 2.4 0.07 5.25 0.03 1.4 0.04 1.9 0.06 3.0 0.11 6 0.04 1.6 0.05 2.2 0.08 3.5 0.14 8 0.07 2.1 0.09 2.9 0.15 4.6 0.25 10 0.11 2.7 0.14 3.6 0.23 5.8 0.40 12 0.15 3.2 0.21 4.4 0.33 6.9 0.57 14 0.21 3.8 0.28 5.1 0.45 8.1 0.77 16 0.27 4.3 0.37 5.8 0.58 9.2 1.01 18 0.34 4.8 0.47 6.6 0.74 10.4 1.28 20 0.42 5.4 0.58 7.3 0.91 11.5 1.58 22 0.51 5.9 0.70 8.0 1.10 12.7 1.91 24 0.61 6.4 0.83 8.7 1.31 13.9 2.28 25 0.66 6.7 0.90 9.1 1.43 14.4 2.47 26 0.72 7.0 0.97 9.5 1.54 15.0 2.67 28 0.83 7.5 1.13 10.2 1.79 16.2 3.10 30 0.95 8.0 1.29 10.9 2.05 17.3 3.56 32 1.08 8.6 1.47 11.6 2.34 18.5 4.04 34 1.22 9.1 1.66 12.4 2.64 19.6 4.57 36 1.37 9.6 1.86 13.1 2.96 20.8 5.12 38 1.53 10.2 2.08 13.8 3.29 21.9 5.70 40 1.69 10.7 2.30 14.6 3.65 23.1 6.32 RECTANGLE Weight of Weld Metal in KG/M of weld W (Width in mm) 1 2 3 4 5 6 7 6 0.05 0.09 0.14 0.19 0.24 0.28 0.33 8 0.06 0.13 0.19 0.25 0.32 0.38 0.44 10 0.08 0.16 0.24 0.32 0.40 0.47 0.55 12 0.09 0.19 0.28 0.38 0.47 0.57 0.66 14 0.11 0.22 0.33 0.44 0.55 0.66 0.77 16 0.13 0.25 0.38 0.51 0.63 0.76 0.88 18 0.14 0.28 0.43 0.57 0.71 0.85 1.00 20 0.16 0.32 0.47 0.63 0.79 0.95 1.11 22 0.17 0.35 0.52 0.70 0.87 1.04 1.22 24 0.19 0.38 0.57 0.76 0.95 1.14 1.33 25 0.20 0.40 0.59 0.79 0.99 1.19 1.38 26 0.21 0.41 0.62 0.82 1.03 1.23 1.44 28 0.22 0.44 0.66 0.88 1.11 1.33 1.55 30 0.24 0.47 0.71 0.95 1.19 1.42 1.66 32 0.25 0.51 0.76 1.01 1.26 1.52 1.77 34 0.27 0.54 0.81 1.07 1.34 1.61 1.88

TRIANGLE

Where T = Plate Thickness W = Width for Cap X = Bevel angle

RECTANGLE

W 3.2 4.2 5.3 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 22.0 24.0 25.0 26.0 28.0 30.0 32.0 34.0 36.0 38.0 40.0 8 0.38 0.51 0.63 0.76 0.88 1.01 1.14 1.26 1.39 1.52 1.58 1.64 1.77 1.90 2.02 2.15

F 6.0 8.0 10.0 11.4 15.2 19.0 22.8 26.7 30.5 34.3 38.1 41.9 45.7 47.6 49.5 53.3 57.1 60.9 64.7 68.5 72.3 76.1 9 0.43 0.57 0.71 0.85 1.00 1.14 1.28 1.42 1.56 1.71 1.78 1.85 1.99 2.13 2.28 2.42

60 KG/M 0.07 0.12 0.19 0.25 0.44 0.68 0.99 1.34 1.75 2.22 2.74 3.31 3.94 4.28 4.62 5.36 6.16 7.01 7.91 8.87 9.88 10.9 10 0.47 0.63 0.79 0.95 1.11 1.26 1.42 1.58 1.74 1.90 1.98 2.05 2.21 2.37 2.53 2.69

W 5.5 7.3 9.1 10.4 13.9 17.3 20.8 24.2 27.7 31.2 34.6 38.1 41.6 43.3 45.0 48.5 52.0 55.4 58.9 62.4 65.8 69.3 12 0.57 0.76 0.95 1.14 1.33 1.52 1.71 1.90 2.09 2.28 2.37 2.46 2.65 2.84 3.03 3.22

70 KG/M 0.11 0.19 0.30 0.39 0.69 1.09 1.56 2.13 2.78 3.52 4.34 5.25 6.25 6.78 7.34 8.51 9.77 11.1 12.5 14.1 15.7 17.4 15 0.71 0.95 1.19 1.42 1.66 1.90 2.13 2.37 2.61 2.84 2.96 3.08 3.32 3.56 3.79 4.03

W 8.7 11.5 14.4 16.5 22.0 27.5 33.0 38.5 44.0 49.5 54.9 60.4 65.9 68.7 71.4 76.9 82.4 87.9 93.4 98.9 104 110 20 0.95 1.26 1.58 1.90 2.21 2.53 2.84 3.16 3.48 3.79 3.95 4.11 4.42 4.74 5.06 5.37

Where T = Plate Thickness W = Width

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T (Plate Thickness in mm)

A (Plate Thickness in mm)

TECHNICAL

DEPOSITION DATA
CAP Weight of Weld Metal in KG/M of weld CH (Cap Height in mm) 1 1.5 2 2.5 3 5 0.03 0.04 0.06 0.07 0.09 6 0.04 0.05 0.07 0.09 0.11 7 0.04 0.06 0.08 0.10 0.12 8 0.05 0.07 0.09 0.12 0.14 10 0.06 0.09 0.12 0.15 0.18 12 0.07 0.11 0.14 0.18 0.21 14 0.08 0.12 0.17 0.21 0.25 15 0.09 0.13 0.18 0.22 0.27 16 0.09 0.14 0.19 0.24 0.28 18 0.11 0.16 0.21 0.27 0.32 20 0.12 0.18 0.24 0.30 0.36 22 0.13 0.20 0.26 0.33 0.39 24 0.14 0.21 0.28 0.36 0.43 25 0.15 0.22 0.30 0.37 0.44 26 0.15 0.23 0.31 0.39 0.46 28 0.17 0.25 0.33 0.41 0.50 30 0.18 0.27 0.36 0.44 0.53 35 0.21 0.31 0.41 0.52 0.62 40 0.24 0.36 0.47 0.59 0.71 4 0.12 0.14 0.17 0.19 0.24 0.28 0.33 0.36 0.38 0.43 0.47 0.52 0.57 0.59 0.62 0.66 0.71 0.83 0.95 5 0.15 0.18 0.21 0.24 0.30 0.36 0.41 0.44 0.47 0.53 0.59 0.65 0.71 0.74 0.77 0.83 0.89 1.04 1.19 6 0.18 0.21 0.25 0.28 0.36 0.43 0.50 0.53 0.57 0.64 0.71 0.78 0.85 0.89 0.92 1.00 1.07 1.24 1.42

CAP
CH CW Where CH = Cap Height CW = Cap Width

CW (Cap Width in mm)

6
CIGWELD SOLID AND FLUX CORED WIRES, DEPOSITION AND WELD METAL RECOVERY RATES
The following Table lists some popular CIGWELD consumables and their Deposition and Weld Metal Recovery Rates: CIGWELD Product Size (mm) Volts Amps WFS m/min Deposition Rate kg/hrWeld Metal Recovery Autocraft LW1-6 0.8 20 150 12.0 2.5 96% Autocraft LW1-6 0.9 26 180 12.0 3.1 96% Autocraft LW1-6 1.0 28 240 13.5 4.8 95% Autocraft LW1-6 1.2 32 300 10.8 5.6 97% Autocraft Silicon Bronze 0.9 24 180 13.2 3.2 95% Autocraft 316LSi 0.9 22 180 10.0 2.8 97% Autocraft 316LSi 1.2 26 250 8.5 4.4 98% Autocraft AL5356 1.0 22 180 16.3 1.5 90% Autocraft AL5356 1.2 24 220 14.0 2.5 92% Satin-Cor XP 1.6 28 300 5.5 4.3 86% Satin-Cor XP 1.6 29 350 6.5 5.4 87% Satin-Cor XP 1.6 30 400 7.0 6.0 89% Satin-Cor XP 2.4 30 400 4.2 5.7 85% Satin-Cor XP 2.4 31 450 5.0 6.8 86% Satin-Cor XP 2.4 32 500 6.0 8.2 90% Verti-Cor 3XP 1.2 25 200 6.7 2.7 86% Verti-Cor 3XP 1.2 26 250 9.9 3.8 84% Verti-Cor 3XP 1.2 28 320 15.0 5.9 88% Verti-Cor 3XP 1.6 27 300 6.2 4.1 86% Verti-Cor 3XP 1.6 28 350 9.5 6.4 81% Verti-Cor 3XP 1.6 29 400 12.0 8.1 88% Metal-Cor XP 1.2 26 250 10.0 5.0 92% Metal-Cor XP 1.6 28 350 6.6 5.6 94% Supre-or 5 1.2 22 170 7.8 2.3 86% Supre-Cor 5 1.6 26 320 5.9 3.3 89% Tensi-Cor 110TXP 1.6 28 280 5.0 3.0 88% Tensi-Cor 110TXP 2.4 29 400 3.8 5.8 90% Shieldcrome 309LT 1.2 26 190 11.4 3.7 84% Shield-Cor 4XP 2.4 29 375 5.4 7.0 84% Shield-Cor 4XP 3.0 30 500 2.9 6.7 86% Shield-Cor 15 0.9 17 120 3.9 0.7 75% Shield-Cor 11 1.2 17 150 3.0 1.0 80% The information provided in this table is based on welding with constant voltage (C.V.) GMA Welding machines. Results may vary and are influenced on the job by shielding gases used, machine settings, stick out, spatter losses, wire sniped off before starts etc.

MANUAL ARC ELECTRODE CONSUMPTION CALCULATOR GUIDE

Instructions for Use of this Data The following tables provide data on the approximate mass in kilograms required of the different types of electrodes for welding the various weld joints used throughout industry today. This data will aid in estimating material requirements and costs. The basis for the following tabulations is given below. Where variations from the given conditions or joint preparations are encountered,adjustmentsinthetabulatedvaluesmustbemadetocompensate for such differences. Basis of Calculations Electrode requirements have been calculated as follows: Where M = Mass of electrodes required D = Mass of weld metal to be deposited E = Proportion of electrode lost M = D 1-E To arrive at the mass of weld metal to be deposited it is necessary to calculate first the volume of metal to be added (area of the cross section of the weld multiplied by the length). This volumetric value is converted to mass by multiplying by the factor 0.0079 kilograms per cubic centimetre for steel. Copyright Produced with the permission of CIGWELD 1300 WELDER (1300 935 337)

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DEPOSITION DATA
SQUARE BUTT JOINTS, WELDED BOTH SIDES
Joint Dimensions Plate Thickness 3mm 5mm 6mm Root Gap (R) 0 1mm 1mm 1.6mm 1.6mm 2.5mm ** Height of Reinforcement = 2mm. kg of electrodes per linear metre of weld* (Approx.) With Reinforcement** 0.23 0.26 0.38 0.41 0.48 0.56 kg of weldmetal deposited per liner metre of weld (Approx.) With Reinforcement** 0.14 0.16 0.23 0.25 0.29 0.34

* Includes spatter losses and 50mm stub end loss.

HORIZONTAL-VERTICAL (HV) FILLET WELDS

Fillet Weld leg length Dimensions kg of electrodes per linear metre of weld* (Approx.) 0.06 0.16 0.24 0.42 0.65 0.95 1.68 2.62 4.10 kg of weldmetal deposited per iner metre of weld (Approx.) 0.04 0.10 0.14 0.25 0.39 0.57 1.01 1.57 2.46

3mm 5mm 6mm 8mm 10mm 12mm 16mm 20mm 25mm

* Fillet weld figures are calculated based on true mitre fillets. Convex or overwelded fillets can increase these figures by 33% or more.

SINGLE VEE BUTT JOINTS, (SINGLE GROOVE BUTTS)

Fillet Weld leg length Dimensions Plate Root Thickness Face (F) 6mm 8mm 10mm 12mm 16mm 20mm 25mm 1.6mm 1.6mm 1.6mm 3mm 3mm 3mm 3mm Root Gap (R) 1.6mm 1.6mm 1.6mm 3mm 3mm 3mm 3mm kg of electrodes per linear metre of weld* (Approx.) With Reinforcement** 0.39 0.63 0.87 1.33 2.22 3.37 5.14 kg of weldmetal deposited per iner metre of weld (Approx.) With Reinforcement** 0.23 0.38 0.52 0.80 1.33 2.02 3.08

* Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm.

DOUBLE VEE BUTT JOINTS, WELDED BOTH SIDES (DOUBLE GROOVE BUTTS)
Fillet Weld leg length Dimensions Plate Root Thickness Face (F) 12mm 16mm 20mm 25mm 1.6mm 1.6mm 1.6mm 3mm Root Gap (R) 1.6mm 1.6mm 1.6mm 3mm kg of electrodes per linear metre of weld* (Approx.) With Reinforcement** 0.92 1.46 2.12 3.33 kg of weldmetal deposited per iner metre of weld (Approx.) With Reinforcement** 0.55 0.88 1.27 2.00

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TECHNICAL

* Includes spatter, 50mm stub ends and back gouging losses. ** Height of Reinforcement = 2mm.

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DEPOSITION DATA
1. GAS METAL ARC WELDING (GMAW - MIG) WIRES FOR MILD AND LOW ALLOY STEELS
WIRE SIZE (mm) gms of wire per metre metres of wire per kg 0.6 2.2 450 0.8 4 254 0.9 4.85 200 1.2 8.5 113 1.6 15.7 63

2. FLUX CORED ARC WELDING (FCAW) WIRES FOR MILD AND LOW ALLOY STEELS
WIRE SIZE (mm) gms of wire per metre metres of wire per kg 1.2 7.5 132 1.6 13 77 2.0 21 50 2.4 28.5 36

3. SUBMERGED ARC WELDING (SAW) WIRES FOR MILD AND LOW ALLOY STEELS
WIRE SIZE (mm) gms of wire per metre metres of wire per kg 2.4 35.5 28 3.2 63 16

4. STAINLESS STEEL GAS METAL ARC WELDING (GMAW - MIG) WIRES

WIRE SIZE (mm) gms of wire per metre metres of wire per kg 0.9 5.1 198 1.2 9 111 1.6 16 63

5. ALUMINIUM GAS METAL ARC WELDING (GMAW - MIG) WIRES

WIRE SIZE (mm) gms of wire per metre metres of wire per kg 0.9 1.7 582 1.2 3.1 327.5 1.6 5.4 184

6. AUTOPAK GAS METAL ARC WELDING (GMAW - MIG) WIRES

WIRE SIZE (mm) gms of wire per metre km of wire / 300kg Pack 0.9 4.85 62 1.0 6.1 49 1.2 8.5 35 1.6 15.7 16 (250kg Pack)

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