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> Technical Knowledge > Job Knowledge > Calculating weld volume and weight
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Job Knowledge 95
Calculating the volume of a weld is one of the first steps to be taken when estimating the cost of
making a weld.
With this information, and knowing the deposition rate of the process, it is possible to determine
the arc time (the length of time that an arc is burning and depositing weld metal) and the amount
of welding consumables required to fill the joint. Both of these are required in order to calculate
the cost of making the weld. Costing will be dealt with in future Job Knowledge articles.
Determining the volume of a weld requires some knowledge of basic geometrical calculations to
determine the area of the weld and multiply this figure by its length. The first step then is to
calculate the cross sectional area of the joint.
With a fillet weld or a 45 single bevel joint this is relatively simple but the calculations become
lengthier as the weld preparation becomes more complex. Fig.1 illustrates how simple this
calculation is for an equal leg length fillet weld; the area of such a weld is half the square of the
leg length, Z. When using this formula do not forget that welders seldom deposit precisely the size
of weld called up on the drawing or in the welding procedure and that there may be some excess
weld metal on the face of the weld.
Calculating the weight of weld metal in double sided V-joints uses the same approach by dividing
the weld into its individual 'V's and adding the products.
A J-preparation, however, adds another area into the equation; that of the half circle at the root of
the weld, see Fig.4 . The formulae given above to calculate 'c', the area of the two red components
and the excess weld metal remain unchanged but the width of the cap must be increased by 2r.
There are also the two areas, 'A' and 'B', to calculate and the two white root radius areas to be
added to the total.
notation as in Fig.3)
The relevant formulae are thus:
1. the dimension 'c' is given by (tan b x (t-r)); the total area of the two red regions is
therefore given by the formula 2((t-r)(tan b x (t-r))/2 or ((t.-r)(tan b x (t-r)).
2. the width of the weld cap, w, is given by w = 2(tan b x (t-r)) + g +2r.
3. the area of the excess weld metal is given by the formula (w x h)/2.
4. the area 'A' is (t-r) x (2r +g).
5. the area 'B' is g x r.
6. the root radius area is (r2 )/4
For a double-U preparation it is necessary to calculate the areas of both sides and add these
together.
Having calculated the weight of weld metal required to fill a weld preparation it is then possible to
calculate the weight of filler metal required (these two figures are not necessarily the same) and to
estimate the time required to deposit this weld metal; both essential in order to arrive at a cost of
fabricating the weld. This will be covered in future Job Knowledge articles.
This article was written by Gene Mathers.
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