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SHEET TWF·T-04 REV 2026-08-20 METHOD M.2026-08-20.1

Weld volume & filler metal

Theoretical weld area, volume, deposited mass and input filler mass from entered joint geometry, weld length, density and deposition efficiency — real consumption moves with profile, penetration and procedure.

Classification Geometry and material planning estimate

InputsT-04
F-01 Weld geometry

Equal-leg fillet or the square-groove planning rectangle.

F-02
mm

Equal leg z, greater than 0; theoretical area is z² ÷ 2.

F-05
mm

Total weld length, greater than 0.

F-06
g/cm³

You supply this figure — 7.85 is the clearly labelled carbon-steel example, not a default.

F-07

Over 0 and at most 1, from your own process data — 0.85 in the worked example.

JavaScript is off in this browser, so no live record can be issued. The worked example below walks the full method with real figures, and the blank card on this page prints as a worksheet.

R-VOL-nnn

Weld volume & filler metal

Awaiting inputs — enter values and issue a record. Empty slots below print as a blank worksheet.

Field slots

F-01Weld geometry
F-05Weld length
F-06Material density
F-07Deposition efficiency
RECORD VOID — inputs changed since issue. Recalculate to issue a new record.

Worksheet · https://theweldfab.com/tools/weld-volume-filler-metal-calculator/ · METHOD M.2026-08-20.1 · REV 2026-08-20

Worked example

STATIC — not a live result

A 6 mm equal-leg fillet, 1,000 mm long, at an entered density of 7.85 g/cm³ and an entered deposition efficiency of 0.85: area 18 mm², volume 18 cm³, deposited mass 141.3 g, input filler mass ≈ 166.2 g.

R-VOL-EX

Weld volume & filler metal

Planning estimate

≈ 166.2 g of filler to put in

Entered assumptions

F-01Weld geometryEqual-leg fillet
F-02Fillet leg length6 mm
F-05Weld length1000 mm
F-06Material density (entered)7.85 g/cm³
F-07Deposition efficiency (entered)0.85

Planning figures

R-01Theoretical weld area18 mm²
R-02Theoretical weld volume18 cm³
R-03Deposited mass141.3 g
R-04Input filler mass at entered efficiency166.2353 g

Planning support only — verify against nameplate/manufacturer data.

RECORD VOID — inputs changed since issue. Recalculate to issue a new record.

Method

M.2026-08-20.1

The theoretical cross-section comes from the geometry you pick: an equal-leg fillet uses area mm² = z² ÷ 2; a square-groove planning rectangle uses area mm² = width × depth. Then:

  • volume cm³ = area mm² × length mm ÷ 1000
  • deposited mass g = volume × density g/cm³
  • input filler mass g = deposited mass ÷ deposition efficiency

Worked figures: a 6 mm equal-leg fillet gives 18 mm² of area; over 1,000 mm that is 18 cm³; at an entered 7.85 g/cm³ the deposited mass is 141.3 g; at an entered 0.85 efficiency the input filler mass is 166.2353 g.

Limits & stop conditions

T-04
  • Theoretical geometry only: actual profile, penetration, reinforcement, the process and your procedure data all change real consumption.
  • Density and deposition efficiency are figures you supply — 7.85 g/cm³ and 0.85 are labelled worked-example values, not defaults this tool asserts.
  • HOLD — dimensions, density or efficiency outside their stated ranges keep the record unissued; nothing is estimated around a bad entry.

Source register

  1. S1 Metal Inert Gas (MIG) Welding — Process and Applications (Job Knowledge 4) ↗ TWI Ltd retrieved 2026-08-19
Bench Awaiting values