Calculators

Current, electrode and gas consumption, heat input, carbon equivalent — all worked out in the browser, nothing sent to a server.

• Welding current by electrode diameter How many amps for a 2.5, 3.2 or 4 mm stick electrode: the calculator corrects for position and covering, with a ready current table next to it.
• Electrode consumption How many 2.5, 3.2 and 4 mm electrodes fit in a kilo and how many go into a metre of weld: the calculator gives pieces, kilos and stub loss.
• Cost per metre of weld What a metre of weld actually costs: deposited metal, wire and gas consumption, electricity, labour hours and the shop rate.
• Preheat temperature Whether to preheat and to what temperature: method B of EN 1011-2 with CET, plate thickness, hydrogen scale and heat input.
• Acceptance limits ISO 5817 Limits for undercut, porosity, excess weld metal and misalignment at quality levels B, C and D for a given wall thickness.
• pWPS generator Pick the process, material group and thickness — the generator drafts the pWPS to ISO 15609-1: edge preparation, filler, gas, current and thermal regime. Download and complete it.
• VT report Give the quality level, weld type and thickness — the generator builds the VT report: test conditions to ISO 17637 and the acceptance table to ISO 5817.
• Weld schedule Enter the welds of the item: type, size, length and quantity. The calculator gives the ISO 2553 designation, the section, the deposited metal and the filler, time and gas.
• Bill of materials List the catalogue sections and the items by dimensions: the calculator gives the mass of each, the total with a cutting allowance and the cost of the steel.
• Cutting plan Give the part lengths and quantities: the calculator lays them out on stock bars and returns the number of bars, the real offcut in millimetres and per cent, and a cutting card.
• WPQR range of qualification Enter the test piece data and the calculator returns the level 2 range of qualification to EN ISO 15614-1: thickness, diameter, positions, heat input, preheat and interpass.
• Qualification range EN ISO 9606 Enter thickness, pipe diameter and position: 10 mm plate covers 3–20 mm, 60.3 pipe from 30.2 mm, PF covers PA, PB and PF, H-L045 all. Plus the six-monthly signature date.
• Wire feed speed Wire feed speed from the current, or current from the feed speed, for solid wire of 0.8 to 1.6 mm, with the deposition rate per hour.
• Duty cycle and fuse size How long the machine may weld before it trips on thermal overload, and what supply fuse or breaker its input current really needs.
• Tungsten electrode selection Which tungsten to use and at what diameter: current range by type and polarity, the colour code and the tip grind angle for the job.
• Shielding gas selection M21 = Ar + 15–25 % CO₂ for steel, M12 for stainless, pure argon I1 for aluminium and TIG. Gives the mix, the EN ISO 14175 code and the flow in l/min.
• Fillet weld: throat and leg Converting throat thickness a into leg length z and back, with the deposited area and the mass of filler metal per metre of fillet.
• Welding unit converter 35 cfh = 16.5 l/min, 300 ipm = 7.6 m/min, 1 ksi = 6.895 MPa: convert AWS and ASME data-sheet units, with worked examples and traps.
• Shielding gas consumption 40 l at 200 bar = 8,000 l of gas, about 11 h of arc at 12 l/min. Gas per shift, what is left from the gauge, CO₂ by weight, CFH to l/min.
• Steel weight calculator Mass of rolled metal by size: sheet, round and square bar, tube, angle and channel, for carbon steel, stainless and aluminium.
• Steel beam weight IPE 200 — 22.4 kg/m, IPE 300 — 42.2, HEB 200 — 61.3, HEA 300 — 88.3. Full EN 10365 and DIN 1025-1 tables and a calculator for length and quantity.
• Steel channel weight UPN 100 — 10.6 kg/m, UPN 120 — 13.4, UPN 160 — 18.8, UPN 200 — 25.3. Weight of 6 m and 12 m bars and of a whole order, and UPN vs UPE explained.
• Steel angle weight L 50×50×5 — 3.77 kg/m, L 100×100×10 — 15.0. Every size to EN 10056-1 with 6 m and 12 m bar weights and a calculator for length and quantity.
• Tube and hollow section Weight of round tube and hollow section from dimensions: diameter or sides plus wall thickness. Common commercial sizes to EN 10219 and the area formulas.
• Sheet metal weight Steel 1 mm = 7.85 kg/m², 2 mm — 15.7, 5 mm — 39.25. Weight of a 1250×2500 or 1500×3000 sheet and of a whole batch, with worked examples.
• Aluminium weight Weight of aluminium products: density of alloys 1050, 5083, 6060 and 6082, the ratio to steel, and a sheet mass table for the usual thicknesses.
• Aluminium sheet The weight of aluminium sheet from 1 to 10 mm thick: kilograms per square metre, cross-section and a calculator for any sheet size.
• Aluminium box section The weight of aluminium box section: twelve common sizes from 15×15×2 to 80×80×4 with the mass per metre and a calculator for any section.
• Aluminium tube The weight of round aluminium tube from 12×1 to 80×3: cross-section, kilograms per metre and a calculator for any diameter and wall.
• Aluminium angle The weight of aluminium angle from 15×15×2 to 80×80×6: cross-section, kilograms per metre and a calculator for any leg and thickness.
• Aluminium flat bar The weight of aluminium flat bar from 15×2 to 100×10: cross-section, kilograms per metre and a calculator for any width and thickness.
• Aluminium round bar The weight of aluminium round bar from 6 to 50 mm: cross-section, kilograms per metre and a calculator for any diameter.
• Carbon equivalent CE Carbon equivalent from the composition on the mill certificate: IIW CE and CET, and what they say about weldability and preheat.
• Shade number DIN Which shade number to set on the helmet for MMA, MIG/MAG, TIG or cutting at a given current, following EN 169 and EN 379.
• Heat input Heat input from current, voltage and travel speed, with the k factor for each process (ISO/TR 18491, EN 1011-1), limits in a WPS and step-by-step examples.
• Cooling time t8/5 10 mm plate at 1.2 kJ/mm cools 800→500 °C in 14.7 s, 20 mm in 5.7 s. EN 1011-2 2D/3D formulas, a t8/5 table by heat input and the 5–25 s window.
• Hardness: HV, HB, HRC Convert HV, HB and HRC both ways: 300 HV = 285 HB = 29.8 HRC, 700 HV = 60.1 HRC. Full ISO 18265 table, tensile strength, worked examples and the 380 HV10 HAZ limit.
• Deposited metal and passes Work out the groove cross-section, the deposit per metre, the consumable with losses, the number of passes and the arc time for V, X, square-edge and fillet welds.
• Groove preparation Give the thickness, the process and the access to the joint; the calculator proposes the preparation type, angle, root gap and root face from the usual ISO 9692-1 tables.
• Chromium and nickel equivalents Enter both parent metals and the filler: get Cr-eq and Ni-eq, the weld point on the Schaeffler diagram and the risk zone — cracks, martensite, sigma. 309L example.
• Wire length on a spool A 15 kg spool of 1.0 mm wire is about 2,430 m, 5 kg about 810 m; 0.8 mm gives 3,800 and 1,270 m. Length from mass and diameter, arc minutes, what is left.
• Cable voltage drop 200 A over 20 m loses 5.6 V on 25 mm² copper and 2.8 V on 50 mm². Volts lost, share of arc voltage and cable heat, with worked examples.
• Generator for a welder A 200 A stick inverter needs about 9 kVA with PFC and 12.5 kVA without. Size from I₁max on the plate, compare kVA not kW, and switch eco mode off.
• Welding cable size Which cable cross-section a given current and cable length need, and how much voltage a long run costs you at the arc.
• Project calculators Six calculators that work out a whole project rather than a single figure: cutting list, mass of steel, length of welds and current. Bench, gate, carport, canopy, fence, stairs.