What it does. The weld metal and the consumables for a list of welded joints. For each joint the cross-section is worked out from its preparation: the groove of a square, single-V, double-V, single-bevel, double-bevel, U or J butt weld with its cap and root, or a fillet weld with its convexity. Its area times the weld length and the density gives the weld metal; the efficiency of each process gives the consumables.
How to use. Add each joint of the job: its type and process, the thickness t and the preparation from the WPS (angle, gap b, root face c, radius R; an empty field takes the typical value shown in it), or the throat a or leg z of a fillet weld, the length of one weld (or the pipe OD) and the number of welds. Choose the material; the cap, root and convexity apply to all joints. In Consumables, set the size and, from the data sheet, the efficiency and deposition rate of each process, and prices if you want the cost. A value outside the allowed range is marked and not used; the message gives the range.
Reading the result. Each row shows the area and the weld metal of the joint. The result window gives the filler metal to buy in kg; the result lists per process the electrodes and packets, the wire and spools, the flux, the arc time, the shielding gas and the cost, and the work shows every step. Chart shows the weld metal of each joint.
Formula. Weld metal = area × length × number × density. Cap, root and convexity: 2/3 × width × height. Consumable = weld metal ÷ efficiency (typically 60 % for covered electrodes, 85 % for flux-cored and 95 % for solid wire). Electrodes = weld metal ÷ weld metal per electrode (typically the core wire of the length burnt, without the stub). Arc time = weld metal ÷ deposition rate; gas = flow × arc time. Not included: tack welds, repairs, back gouging, run-on and run-off plates.
Glossary
- Weld metal
- The metal deposited in the joint: the groove, the cap and the root.
- Efficiency
- Weld metal per mass of consumable; the losses are spatter, slag, stubs and wire ends.
- Deposition rate
- Weld metal deposited per hour of arc time, kg/h.
- Root face c
- The flat part of the edge at the root, not bevelled.
- Throat a, leg z
- Size of a fillet weld; for equal legs a = z / √2.
