# Filler Metal Consumption Calculator for Wire and Electrodes

> Source: https://netray.co/tools/filler-metal-consumption-calculator
> Publisher: Netray (netray.co), AI and integration engineering for ERP and manufacturing systems.
> Section: Free Tools

## Short answer

Turns weld metal per meter, joint length and deposition efficiency into kilograms of filler to buy and the number of spools or boxes.

## Category

supply-chain

## Industry

Fabrication

## Audience

- Buyer
- Welding engineer
- Production planner

## Tool

**Kind:** calculator

**Inputs:**

#### Weld metal per meter

**Key:** wm_per_m

**Type:** number

**Default:** 0.8

**Min:** 0

**Step:** 0.01

**Unit:** kg/m

#### Weld length per assembly

**Key:** length

**Type:** number

**Default:** 6

**Min:** 0

**Step:** 0.5

**Unit:** m

#### Number of assemblies

**Key:** qty

**Type:** number

**Default:** 40

**Min:** 1

**Step:** 1

**Unit:** pcs

#### Deposition efficiency

**Key:** de

**Type:** slider

**Default:** 90

**Min:** 50

**Max:** 100

**Step:** 1

**Unit:** %

**Help:** GMAW solid wire 90-98, FCAW 80-90, SAW about 95-99, SMAW 55-70 after stub loss.

#### Allowance for rework and waste

**Key:** scrap

**Type:** slider

**Default:** 8

**Min:** 0

**Max:** 30

**Step:** 1

**Unit:** %

#### Pack size (spool or box)

**Key:** pack

**Type:** number

**Default:** 15

**Min:** 0.5

**Step:** 0.5

**Unit:** kg

#### Price per kg

**Key:** price

**Type:** number

**Default:** 3.4

**Min:** 0

**Step:** 0.1

**Unit:** $/kg

**Outputs:**

#### Weld metal to deposit

**Key:** wm_total

**Expr:** wm_per_m * length * qty

**Format:** decimal

**Description:** Kilograms.

#### Filler required

**Key:** need

**Expr:** wm_total / (de / 100) * (1 + scrap / 100)

**Format:** decimal

**Primary:** true

**Description:** Kilograms including losses and allowance.

#### Packs to order

**Key:** packs

**Expr:** ceil(need / pack)

**Format:** integer

**Primary:** true

#### Weight ordered

**Key:** buy_kg

**Expr:** packs * pack

**Format:** decimal

**Description:** Kilograms after rounding up.

#### Material cost

**Key:** cost

**Expr:** buy_kg * price

**Format:** currency

#### Expected leftover

**Key:** left

**Expr:** buy_kg - need

**Format:** decimal

**Description:** Kilograms in the last pack.

**Chart:**

#### Filler required vs deposition efficiency

**Type:** line

**X:** de

**From:** 50

**To:** 100

**Steps:** 26

**Series:**

- need

**Disclaimer:** Estimate for purchasing. Actual use varies with fit-up, welder skill, process settings and stub length practice.

## Content

**Intro:** Buyers and planners need to know how much wire or electrode to order for a job. This calculator converts weld metal weight into filler to purchase and rounds up to whole packs.

**Sections:**

#### How to use it

**Body:** Enter the weld metal per meter, which you can get from the weld metal volume calculator, then the weld length per assembly and the quantity. Choose the deposition efficiency for your process and an allowance for rework. Enter the pack size and price to see the number of packs and cost.

**Bullets:**

- Use real deposition efficiency per process
- Allowance covers repair and setup waste
- Round up to whole packs
- Update after actual consumption data

#### Deposition efficiency explained

**Body:** Deposition efficiency is the share of purchased filler that ends up in the weld. Solid wire GMAW loses only a little to spatter. Flux cored wire loses more to slag and spatter. Stick electrodes lose the unused stub and coating weight, so efficiency counts the weight of the whole electrode. Submerged arc is very efficient but flux is separate and is not counted here.

#### Worked example

**Body:** A job needs 0.8 kg of weld metal per meter, 6 m per assembly and 40 assemblies. That is 192 kg deposited. At 90 percent efficiency and an 8 percent allowance, the filler needed is about 230 kg, which is 16 packs of 15 kg. The calculator shows the leftover so you can see whether a smaller pack would waste less.

#### Common mistakes

**Body:** Teams order from net weld weight without efficiency, ignore stub loss on stick electrodes, and forget separate flux for submerged arc. They also order before verifying whether the same wire is already in stock.

**Bullets:**

- No efficiency factor
- Flux not budgeted
- Wrong alloy class
- Stock not checked

**Cta:** Netray can help connect consumable requirements from routings and bills of material to purchasing in your ERP, with expiry and lot traceability.

**Faq:**

#### What deposition efficiency should I use?

**Answer:** Typical ranges are 90 to 98 percent for solid wire GMAW, 80 to 90 for flux cored, 95 to 99 for submerged arc wire, and 55 to 70 for stick electrodes including stub. Use measured data from your own shop if you have it.

#### Is flux included for submerged arc?

**Answer:** No. Flux is a separate consumable, often used at roughly one kilogram per kilogram of wire, but the ratio varies. Budget it as its own line using your supplier's data.

#### Why add a rework allowance?

**Answer:** Repairs, test welds, tack welds, setup, and cutting wire at spool changes all consume filler that never appears in the nominal joint volume. A single-digit percentage is common but measure your actual usage.

#### How do I keep track of lots?

**Answer:** Record filler heat or lot numbers against jobs for traceability where the code requires it. Consumable storage, such as baking low hydrogen electrodes, also matters. An ERP lot control feature can store this with each issue.

## Search terms

filler metal consumption calculator, welding wire consumption calculator, electrode consumption calculator, welding consumables calculation, deposition efficiency welding, how much welding wire do i need, welding rod calculator, filler metal estimate

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