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, combined 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 your test details and the calculator shows the range to EN ISO 9606-1: thicknesses, diameters, positions, joint types and material groups.
• 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 Which shielding gas mixture suits the material and the process: argon, CO2 and their blends for MIG/MAG, TIG and stainless steel.
• 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 Converts what welders actually meet: kJ/mm and kJ/cm, mm/min and m/min, bar and MPa, inches and millimetres, °C and °F.
• Shielding gas consumption How much gas a given flow rate uses and how long the cylinder lasts: volume from pressure, working time and the cost per weld.
• 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 120 — 13.4 kg/m, UPN 160 — 18.8. Pick UPN or UPE, enter length and quantity: total mass from the DIN 1026 table, not a formula. Full size table.
• Steel angle weight L 50×50×5 — 3.77 kg/m, L 100×100×10 — 15.0. Every size to EN 10056-1 from 20×20×3 to 200×200×20, unequal legs included, with a calculator.
• 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 sheet 2 mm — 15.7 kg/m², 5 mm — 39.25, 10 mm — 78.5. Mass of a sheet, of a batch and of a square metre for steel, stainless and aluminium.
• 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 thermal efficiency of the process taken from ISO/TR 18491 and EN 1011-1.
• Cooling time t8/5 The cooling time from 800 to 500 °C from heat input, thickness and preheat. Two- and three-dimensional formulas to EN 1011-2, with the transition thickness.
• Hardness: HV, HB, HRC Convert Vickers, Brinell and Rockwell hardness both ways, with the approximate tensile strength and the hardness limits allowed in a weld HAZ.
• 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 Mix two parent metals and the filler by their shares: the calculator gives Cr-eq and Ni-eq and plots the weld on the Schaeffler diagram. Diagram as PNG/SVG.
• Wire length on a spool Wire length from the spool mass and the diameter, mass per metre, arc time at a given feed speed, and the length of weld one spool will cover.
• Cable voltage drop How many volts a lead loses at a given current, length and cross-section, how much of that turns into heat, and when a thicker conductor is needed.
• Generator for a welder What generator rating a welding machine needs: worked out from the rating plate, with a reserve that depends on the machine type.
• 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.