Aluminum Wire Deposition Rate Calculator

The Aluminum Wire Deposition Rate Calculator finds the rate at which a welding wire is converted into weld metal using the electrode diameter, wire feed speed, and electrode efficiency.

INSTRUCTIONS: Choose units and enter the following:

• (`D`) Electrode Diameter
• (`S`) Wire Feed Speed 
• (`E`) Electrode Efficiency

Aluminum Wire Deposition Rate (`R`): The calculator returns the answer in pounds per hour (lb/hr). However this can be automatically converted to compatible units via the pull-down menu.

The Math / Science

The deposition rate is the amount of wire actually converted into weld metal per unit of time, whereas the melt-off rate is the amount of wire being consumed per unit of time. Solid wire can have a range of efficiencies from 88-98%. 

To find the deposition rate, use the formula:

R = 4.32 ⋅ D² ⋅ S ⋅ E

where:

• `R`  = wire deposition rate (lb/hr)
• `4.32` = aluminum constant based on density
• `D` = electrode diameter (in)
• `S` = wire feed speed (in/min)
• `E` = electrode efficiency

Note: the above formula is for Imperial Units.  However, this calculator makes the conversion.

Example

For a solid aluminum wire that is 100% efficient, has a diameter of 0.045 inches, and has a feed speed of 300 inches per minute, what is the deposition rate?

Aluminum deposition rate = 4.32 ⋅ D² ⋅ S ⋅ E

Aluminum deposition rate = 4.32 ⋅ (0.045 inches)² ⋅ (300 in/min) ⋅ 100%

Aluminum deposition rate = 2.6244 lb/hr

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• Weight of Aluminum Square Bars: Computes the average weight of aluminum bars based on the number and dimensions of the bar, and an average density of 2700 kg/m3 for aluminum bars.
• Aluminum Wire Deposition Rate Calculator:  Estimates the rate at which a welding wire is converted into weld metal using the electrode diameter, wire feed speed, and electrode efficiency.
• Welding Heat Input Calculator: Estimates the amount of heat or thermal energy that is introduced to a material when a weld is made using the arc voltage, current, and travel speed.
• Groove Weld Potential Root Cracking Calculator: Determines whether or not the groove weld has a potential for root cracking based on the width-to-depth ratio (1.0-1.4).
• Weight of Hot Rolled Steel Flats: Computes the average weight of steel flats based on the number and dimensions of the flats, and an average density of 7800 kg/m3 for steel flats.
• Modulus of Elasticity for Martensitic Stainless Steel: The measure of stainless steel's tendency to deform elastically when a force is applied.
• Brinell Hardness of Gray Cast Iron: Measure of gray cast iron's ability to resist permanent indentation deformation.
• Weight of Brass Rounds: Computes the weight of any number of brass round bars based on the number of rods, their dimensions, and an average density of 8,600 kg/m³ for brass.

Fabrication Calculators and Constants

• K Factor Calculator
• Aluminum Wire Deposition Rate Calculator
• Steel Wire Deposition Rate Calculator
• Welding Heat Input Calculator
• Groove Weld Potential Root Cracking Calculator
• Weight of Hot Rolled Steel Flats
• Modulus of Elasticity for Martensitic Stainless Steel
• Brinell Hardness of Gray Cast Iron
• Bend Allowance

References

Welding Answers (https://weldinganswers.com/calculation-depostion-rate-on-solid-wires/)