Question on .035 and .045 wire

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Let me see if I can explain myself without too much confusion. We use .035 and .045 solid wire (ER 70S-6), and I'm trying to figure out how much (1lb or we can use 10lbs) of wire burned, how much weld it would yield. ThanksSimon
Reply:Are you asking, how many liner feet of fillet a 1 # spool will yield?
Reply:Yes transit, if you would have that information that would be great,or a website. My superviser went to a meeting and came back with a list of things he needs to look into, and then said the bosses wanted to know if you were to burn 1lb of wire would it weigh 1lb. He said he didn't know if they were testing him or not. So he is looking for something to bring to next weeks meeting.Thanks
Reply:It sounds as if the issue may have to do with weight calculations.Not sure what the project or job is but if 10# of wire is used in the fabrication of an object then that wire weight would have to added to the base weight of the material for a total finished object weight.  For most things I would say it's a mute point but I can also understand where there could be very critical weight considerations.  ??MM200 w/Spoolmatic 1Syncrowave 180SDBobcat 225G Plus - LP/NGMUTT Suitcase WirefeederWC-1S/Spoolmatic 1HF-251D-1PakMaster 100XL '68 Red Face Code #6633 projectStar Jet 21-110Save Second Base!
Reply:Sounds like maybe two questions?? One would be how many feet (inches) a pound will weld out and the other is what is the remaining wieght of deposited filler vs the input wieght. Most solid wires I believe the remaining depostion is in the high 90%'s, like 95% to 99%. Lots of minute variables like what is in the base vs what's in the filler and what burns out vs what stays in.  As to how much is needed per X distance here is a very rough chart. http://www.weldingwire.com/applicati...let%20Weld.pdf
Reply:I Googled to;   calculate weld metal deposition - Google SearchThese are some of the sites I found. Some are easer to understand than others, take your pick. http://www.twi.co.uk/content/jk95.htmlhttp://wiki.answers.com/Q/How_do_you...nd_weight_alsohttp://www.esabna.com/EUWeb/FM_handbook/577fm8_6.htmhttp://www.esabna.com/EUWeb/AWTC/Lesson9_22.htmhttp://www.millerwelds.com/resources...d.php?p=148032http://www.postle.com/welding_cost_f...or_differe.htmLast edited by transit; 12-05-2009 at 01:31 PM.
Reply:I don't have all my figures with me, but if I remember correctly a 12" long 1/4" filet weld requires .112 pounds of weld wire. I figure this for customers all the time that are bidding jobs, as I get calls wanting to know how much weld wire a particular job will take. One note of caution, if you estimate weld wire requirements based on a particular weld size, then the operators put down a larger weld than is neccesary, you will need more wire than what was estimated, I see overwelding at a lot of my accounts, I have had success at a few companies and convinced them to buy all of their welders a basic set of filet weld gauges, and then have worked with them to train the welders to put down the right size weld, if the print calls for a 1/4" weld size, they hold there welders accountable for the correct size weld, overwelding is expensive, not in just shielding gas and wire, but most importantly time. I hate to get on my soapbox, but it really p----ses me off when bean counters call complaining about the cost of weld wire and shielding gas, when in all reality gas and wire only make up about 15% of the total cost to produce a weld, the bulk of the cost is labor, I can save a customer a lot more money by teaching his operators to put down the proper weld size, and setting his machine correctly to eliminate spatter than I can selling him a cheap foreign wire. These bean counters don't realize that reducing the time it takes to produce a product or weld is where the savings are.Last edited by ss42768; 12-05-2009 at 05:41 PM.
Reply:My understanding, there are theoretical and as built numbers...Whatever is specified on the drawing - can be calculated. And practical realization by weldor...Theoretical - we know the area as specified by engineering. So then calculate the volume, so the weight. Then from manuf spec for wire - weight per foot, or whatever there is - we can figure theoretical number... Attached Images
Reply:Thanks for all the information.  I've just printed out all of ya'lls post and I'm going to give it to my superviser so he can read through all the post and determine if any of this is what he thinks the owner is looking for.       Thanks Simon
Reply:Hey Cajun Welder!You can assume an average of 95% deposition effiency for solid wire (it might be a bit higher or lower depending on amperage, spatter, ect), which means you will get around 0.95 lbs of weld metal for every 1 pound of wire (doesn't matter if it is .035" or .045").  The comments on overwelding are bang on the money.  If the weld specified is a 1/4" fillet weld(assuming a flat profile which is 0.129lbs/ft) and the welder puts in a 5/16" fillet weld (again assuming a flat profile which is 0.201lbs/ft), the weld is being "over" welded by nearly 60%!!!
Reply:Thanks Highlandwelder, thats what they are looking for. I talked to the owner today and thats what he was asking my superviser to look into. Superviser was in a hurry to leave for a hunting trip and didn't get all the information. ThanksSimon