Welding Calculator

A
V
in/min
in
in/min
Construction

Calculate welding heat input and electrode/wire consumption for MIG, TIG, or stick welding.

Formula

Heat Input (kJ/in) = (A × V × 60) / (speed_ipm × 1000); Deposition (lbs/hr) = WFS × wire_wt/in × 60
  • Heat input affects grain growth and HAZ toughness. Typical range: 25–100 kJ/in for structural steel.
  • Steel wire density: 0.284 lbs/in³ (7.86 g/cm³).
  • AWS D1.1 structural welding code specifies heat input limits for pre-qualified procedures.

200A, 25V, 12 in/min travel, 0.035 in wire, 300 in/min WFS

Inputs
  • Amperage: 200 A
  • Voltage: 25 V
  • Travel Speed: 12 in/min
  • Wire / Electrode Diameter: 0.035 in
  • Wire Feed Speed (MIG): 300 in/min

Heat input = (200×25×60)/(12×1000) = 25 kJ/in. Deposition = 300 × 0.000273 × 60 = 4.91 lbs/hr.

Frequently asked questions

Why does heat input matter?
High heat input can reduce toughness in the heat-affected zone (HAZ) of high-strength steels and cause distortion. Low heat input can cause lack of fusion. AWS procedures specify acceptable ranges.