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4) That makes a Rectangle with one side still equal to B and the other H.
5) The AREA as defined for a Rectangle is B * H. But remember we duplicated the Blue Triangle so to get the AREA of the
Original Blue Triangle we have to divide by 2 hence the formula: Area = B * H / 2
Area of a Segment (Weld Reinforcement)
This is one Area that is often used in calculating weld metal area and volume; it is called the area of a
Circle Segment and shown in Red on the photo left. This is what is used to calculate the area of Weld
Reinforcement. The accurate way to do this is to calculate the area of a segment of Radius R (that is
the combined Green and Red Areas;) use the length of the Cord W (width of weld) and subtract the
area of the triangle formed by the Cord and distance from the Center of the Circle and the Cord (the
Green Area.) This leaves the Area between the Cord and the Outer Area of the Circle (Red Area) or
Weld Reinforcement in our case.
However we would have to estimate the Radius of the circle making the reinforcement and the angle of
that Segment. Not an easy item to estimate. Since we know the weld bead height (or the desired
maximum height by code, usually 3/32 or 1/8 inch) and the weld height is much smaller than the weld
width we can use a method that estimates the area and is probably better than estimating the radius.
The formula is:
Approximate Area of a Segment (Weld Reinforcement) = (2 H * W) / 3 + H 2 / 2W
Since weld reinforcement is not a perfect circle, the value obtained is sufficiently accurate for any engineering calculations needed.
In fact since weld reinforcement is not a portion of a perfect circle this approach may be closer to the actual area/volume! Having
checked several typical weld reinforcements dimensions you can use 72% of the Area of a Rectangle for the estimate of
reinforcement.
With these basic shapes you can calculate the area of almost all welds.
Look at the following examples of the of weld joints; the weld area can be arranged into Triangles, Rectangles and Segments.
To calculate the weld metal volume that must be added to a weld joint you simply multiply the Area times the Length in the same
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To calculate the weld metal volume that must be added to a weld joint you simply multiply the Area times the Length in the same
dimensions. Therefore if the length is given in feet convert it to inches so all dimensions are in inches.
Therefore Area in2 * Length in = Volume in3. Remember dimensional analysis works to check your work
in 2 * in = in3.
So to get lbs of weld metal needed do you just multiply the volume by the density of the material?
Is that how much you should purchase?
No!
You Must Account for Losses.
For example when Stick Welding the electrode purchased includes flux, youll also throw away the stub and some of what your
depositing will become wasted spatter. The factor that estimates the amount of welding electrode purchased that deposits as weld
metal is called Deposition Efficiency. Stick Electrodes, as youd expect, have the lowest values. Depending on the length, type
of electrode and the amount of stub being thrown away the Deposition Efficiency can vary from as low as 40%, meaning only 40%
of what you purchase will become weld metal to a high of 60%. For general calculations you can use 50%.
The following are some values you can use for various welding processes:
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Therefore divide the weld metal needed by the Deposition Efficiency (as a decimal, i.e. 93% = 0.93) to get how much of the
particular filler material being used needs to be purchased. Therefore if you find 55 lbs of weld metal is needed then you'll need to
purchase 55 lbs/0.93 = 59 lbs of wire or 55 lbs/0.50 = 110 lbs of Stick electrode.
One Other Calculation often used is the length of wire to make a pound. This defines the needed wire feed speed etc.
Well calculate 0.045 solid wire and then give some values you can use:
The area of an 0.045 in diameter wire is = (0.045 2 * 3.1416) / 4 = 0.00159 in2
[Note: 3.1416 is the number obtained when dividing the circumference of any circle by its diameter. It is called by the Greek
Letter that Archimedes used in the 3rd Century BC when he utilized the value in his calculations, () Pi ]
The Volume per foot = Area * 12 in / ft = Volume in3 / ft wire = 0.0191 in3 / ft
Weight = Volume / ft * 0.294 lb / ft = 0.00542 lb / ft. To get ft / lb divide 1 / (lbs/ft) = 184 ft/lb.
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Note how dimensional analysis shows the correct units. Crunch the numbers and youll get:
0.035
0.045
1/16
5/64
3/32
1/8
5/32
305 feet / lb
184 feet / lb
96 feet / lb
61 feet /l b
43 feet / lb
24 feet / lb
15 feet / lb
For metal and flux cored wire the density is somewhat lower than solid wire and is dependent on the specific wire, percentage of
outer sheath, amount of iron power versus flux in the core etc. You could multiply the above values by 1.05 to get an estimate.
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