Deposition Rate Calculator
Free online tool — calculate weld metal deposition rate in lbs/hr and kg/hr from wire feed speed and electrode diameter.
What Your Deposition Rate Means
Deposition rate tells you how many pounds (or kilograms) of weld metal you deposit per hour of arc-on time. It is driven by three variables: wire feed speed, electrode diameter, and wire density. A higher deposition rate means more metal laid down per hour, which directly affects project cost and schedule.
In practice, deposition rate determines how quickly you can fill a joint. Larger electrode diameters and faster wire feed speeds increase deposition but also increase heat input. For multi-pass welds on thick sections, balancing deposition rate against heat input and interpass temperature is essential to avoid overheating the base metal or exceeding WPS parameters.
Typical GMAW deposition rates for structural steel range from 3 to 12 lb/hr depending on wire diameter and WFS. FCAW generally achieves higher rates than solid-wire GMAW at the same amperage. SAW achieves the highest deposition rates of all arc welding processes, often exceeding 15 lb/hr, making it the preferred choice for long, straight seams in shop fabrication.
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Industry-standard formulas