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
Welding Calculators:
- Bend Allowance Calculator: Computes Bend Allowance based on the thickness of the material, bend angle, inside radius, and K factor.
- 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
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/)