Welding calculators
Current, electrode and gas consumption, heat input, carbon equivalent — all worked out in the browser, nothing sent to a server.
The calculations that come up between fitting the joint and running the first bead. Each one works in your browser — nothing is sent anywhere and nothing is stored.
More about the calculators
Under every calculator the formula is written out and the source of the coefficients is named: EN 1011-2, ISO/TR 18491, ISO 5817, EN ISO 6848 or consumable data sheets. That is deliberate. A result you can reproduce by hand is a result you can defend in front of an inspector; "the website said so" is not.
Where to start. Welding with covered electrodes: current by diameter and electrode consumption. Working in shielding gas: gas consumption, wire feed speed and heat input. Before a structural joint that matters: carbon equivalent and preheat temperature. Before quoting: cost per metre of weld. And if the arc feels soft at the end of a long extension, the machine is usually innocent — check the cable cross-section.
All of it is indicative. The final parameters are set by the welding procedure specification and the material certificate.
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Current and settings
- Welding current by electrode diameter 2.5 mm electrode: 70–100 A; 3.2 mm: 90–140 A; 4 mm: 130–190 A in the flat position. The calculator corrects for position and coating and checks the diameter.
- Preheat temperature Whether to preheat and to what temperature: method B of EN 1011-2 with CET, plate thickness, hydrogen scale and heat input.
- Wire feed speed 1.0 mm wire at 130 A runs at about 5.5 m/min, 1.2 mm at 200 A at 5.8 m/min. Feed speed from current or back, 0.8–1.6 mm solid wire, with deposition in kg/h.
- Duty cycle and fuse size Duty cycle at any current: 60 % at 160 A runs nonstop at about 124 A. Plus the input current I₁eff and the C-curve breaker or fuse your welder 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.
- Carbon equivalent CE CE (IIW) and CET from the mill certificate analysis: below 0.40 no preheat, from 0.40 preheat per EN 1011-2. Worked examples for S235, S355, C45; preheat for your thickness.
- Heat input Q = k·U·I·60/(v·1000) kJ/mm: MAG at 220 A, 24 V and 300 mm/min gives 0.84 kJ/mm. k factor per process (EN 1011-1), kJ/cm to kJ/mm, WPS limits, worked 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.
- Chromium and nickel equivalents Cr-eq = Cr + Mo + 1.5Si + 0.5Nb + 2Ti, Ni-eq = Ni + 30C + 0.5Mn. Enter parent metals and filler: the weld point on the Schaeffler diagram and its risk zone.
- 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 150 A over 10 m needs 16 mm², 200 A over 30 m 70 mm²: welding cable size by current and length, a ready table, and the volts a long lead costs at the arc.
Consumption and cost
- Electrode consumption A kilo holds about 44 electrodes of 2.5 mm, 30 of 3 mm, 27 of 3.2 mm and 13 of 4 mm. Full table by rod length, worked example and a calculator per metre of weld.
- Cost per metre of weld How much welding costs: a metre of MAG V weld in 10 mm plate is about €11, 79 % of it labour. Cost per metre, foot and inch from your prices, in your currency.
- Fillet weld: throat and leg Leg z = throat a × 1.414: an a4 fillet has a 5.66 mm leg, a5 — 7.07 mm. Convert a to z and back, with deposited area and filler mass per metre of weld.
- 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.
- Deposited metal and passes 10 mm V butt weld: 0.49 kg of weld metal per metre, 0.53 kg of MAG wire; 20 mm plate: 8 MAG passes. Groove area, deposit, consumable and arc time for V, X 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.
- 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.
- Welding quote calculator Build a welding quote: metal by weight, welding costed from the weld section (wire, gas, power, time), labour, margin and tax. Prints to PDF with your header.
Metal weight and profiles
- 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.
- Steel weight calculator Ø12 round bar — 0.888 kg/m, 40×5 flat bar — 1.57 kg/m, 1 mm sheet — 7.85 kg/m². One calculator for every shape and metal: steel, stainless, aluminium, copper, brass.
- Steel beam weight IPE 200 — 22.4 kg/m, HEB 200 — 61.3 kg/m, HEA 200 — 42.3 kg/m. Weight per meter and per 6 m and 12 m bar from EN 10365 tables, plus a calculator for length and quantity.
- Steel channel weight UPN 100 — 10.6 kg/m, UPN 200 — 25.3 kg/m, UPN 160 — 18.8 kg/m. Weight per meter, per 6 m and 12 m bar and for a whole order, plus 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.
- Beam deflection and stress Deflection, moment and bending stress σ = M/W for IPE, HEA, HEB, UPN, tubes and flat bar in steel, stainless and aluminium. Formulas, IPE 200 example, L/250 and L/300.
- Tube and hollow section 40×40×3 hollow section — 3.30 kg/m, 60×40×3 — 4.25, 42.4×3.2 tube — 3.09 kg/m. Enter size and wall for one piece, a batch or a metre; EN 10219 tables and 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 2 mm sheet — 5.4 kg/m², 40×40×2 box section — 0.821 kg/m, Ø20 bar — 0.848 kg/m. Aluminium (aluminum) weight of sheet, tube, angle, bar; alloy densities, lb/ft.
- 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 Aluminium (aluminum) round tube weight: 20×2 mm is 0.305 kg/m, 30×2 0.475 kg/m, 50×3 1.20 kg/m. Sizes 12×1 to 80×3 and a calculator for any diameter and wall.
- Aluminium angle Aluminium (aluminum) angle weight: 30×30×3 mm is 0.462 kg/m, 40×40×3 0.624 kg/m. Sizes 15×15×2 to 80×80×6 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.
- Stainless steel weight Density of 304 — 7.90 g/cm³, 316L — 8.00. 2 mm sheet 15.80 kg/m², 42.4×2 tube 2.005 kg/m, 40×40×2 box section 2.402 kg/m. Calculator and tables.
- Stainless steel sheet Stainless sheet 1 mm — 7.90 kg/m², 2 mm — 15.80; a 1250×2500×2 sheet 49.4 kg, ×3 74.1 kg. Grades 304 and 316L, thicknesses 0.5–10 mm and a calculator.
- Stainless steel tube Stainless tube 42.4×2 — 2.005 kg/m, 48.3×2 — 2.298, 29×1.5 hygienic (DN25) — 1.024 kg/m. Tables to EN 10217-7, EN 10296-2, DIN 11850 and a calculator.
- Stainless round bar Stainless round bar Ø10 — 0.620 kg/m, Ø20 — 2.482, Ø30 — 5.584 kg/m (304). Mass for 304 and 316L, formula 0.006205·d², square and hexagon bar.
- Rebar Rebar weight: 8 mm — 0.395 kg/m, 10 mm — 0.617, 12 mm — 0.888, 16 mm — 1.578 kg/m; a tonne of 12 mm is 1126 m. Chart 6–40 mm to EN 10080, 6 m and 12 m bars.
- Steel round and square bar Steel round bar Ø10 — 0.617 kg/m, Ø20 — 2.466, Ø30 — 5.549, Ø50 — 15.41 kg/m; 20 mm square — 3.14 kg/m. EN 10060 and EN 10059 tables, formula 0.006165·d².
- Copper weight Copper sheet 1 mm is 8.96 kg/m², Ø10 bar 0.704 kg/m, 15×1 EN 1057 tube 0.391 kg/m. Tables of common sizes, Cu-ETP and Cu-DHP grades, and a calculator.
- Brass weight Brass sheet 1 mm is 8.50 kg/m², Ø20 round bar 2.67 kg/m, 17 mm hex 2.13 kg/m. Densities of CuZn37, CuZn39Pb3 and CuZn40, size tables and a calculator.
- Tread plate weight Steel teardrop plate 3 mm weighs about 26 kg/m², 5 mm 42 kg/m²; aluminium five-bar 2/3.5 is 5.6–5.8 kg/m². Weights of 1000×2000, 1250×2500, 1500×3000 sheets.
- Steel flat bar 40×4 flat bar weighs 1.256 kg/m, 50×5 1.96 and 100×10 7.85 kg/m. Size chart to EN 10058 and EN 10278, 6 m lengths, metres per tonne, galvanized flat and a calculator.
Standards, tolerances and documents
- Acceptance limits ISO 5817 Undercut, pores, excess weld metal, root concavity, misalignment: the ISO 5817 limit at level B, C or D for your thickness, with ready tables for C and B.
- 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.
- 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, diameter, position: 10 mm plate covers 3–20 mm, 60.3 pipe from 30.2 mm, butt PF: PA and PF (PF fillet test: +PB), H-L045 all but PG. Plus the 6-month signature.
- Welder’s log Shifts, hours, metres of weld and joints — and what you have earned this week, this month and on each job.
Drawing tools and more
- Pipe notching template Enter the diameters and the angle: you get a wrap-around template to print at 1:1, wrap round the pipe and cut along. Saddle at 30–90°, hole in the run pipe, segmented bend.
- Cone flat pattern Enter two diameters, the height and the plate thickness: the calculator gives radii R1 and R2, the sector angle, the blank size and mass, draws the pattern and exports DXF.
- 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.
- 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 ISO 16321-2.
- 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.
- Sheet metal bend allowance 2 mm sheet, r = 2 mm, 90° bend, 50 + 50 mm outside flanges — flat length 96.16 mm. Bend allowance, bend deduction, K-factor by DIN 6935 or 0.33/0.44/0.5, min radius.
- Press brake tonnage 2 mm S235 sheet on a V16 die needs about 16.6 t per metre of bend. Tonnage in tonnes, kN and US tons, t/m chart by thickness and V, inside radius 0.16·V, min flange.
- Welding simulator Stick, MIG and TIG in three positions: speed, arc length and angle by hand, real arc sound, ISO 6520-1 imperfections and a cut-open weld at the end.
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Frequently asked questions
Which calculator should I start with?
It depends on the process. With covered electrodes: current by diameter and electrode consumption. In shielding gas: gas consumption and wire feed speed. Before a joint that carries load: carbon equivalent and preheat. Before you quote: cost per metre of weld.
Is anything sent to a server?
No. Every calculation runs in the browser and nothing leaves it. That is also why the calculators keep working with no connection, provided the page has been opened once before.
Can I send a calculation to someone else?
Yes, with the share button. The values you entered go into the page address, so the link opens the calculator with the same numbers — useful for agreeing settings or a price in writing.