Calculate required filler-wire weight, wire length, spool quantity, weld-metal requirement and estimated waste for MIG, MAG and TIG welding jobs.
How do I calculate MIG wire consumption? Estimate the deposited weld-metal mass, divide it by the actual deposition efficiency, then add an appropriate waste allowance.
Can this calculate TIG filler wire? Yes. Select TIG and enter the filler diameter, material density and required deposited weld-metal weight or use the weld-length method.
Why does wire diameter matter? For the same mass, thinner wire has a greater physical length. Diameter also affects feeding, deposition rate and welding parameters.
Can I calculate how many spools I need? Yes. Enter the net weight of one spool or filler pack and the calculator rounds the theoretical requirement up to complete packages.
Does this include wire waste? Yes. The additional-waste percentage is applied after the basic wire requirement has been calculated.
Does the calculator know my exact weld size? No. The weld-metal requirement must come from your joint design, weld-size calculation, measured production data or the length-based input provided here.
Are the density values exact? They are representative values for estimating physical wire length. Actual alloy density can differ, so use manufacturer data when precise wire length is important.
Is this suitable for production planning? It is useful for preliminary material planning. Production estimates should be calibrated against actual consumption for the specific welding process, joint and operator.