Welding & Fabrication worked example

Filler Wire Cost with filler wire deposition rate of 20 lb / hr: a worked example

What does the result look like when filler wire deposition rate reaches 20 lb / hr? The full calculation is worked below with real intermediate numbers. Use it to put a defensible filler wire number on a quote or to compare a flux cored job against an equivalent solid wire job.

The inputs for this scenario

  • Filler wire deposition rate: 20 lb / hr (raised for this scenario; the documented default is 8)
  • Arc-on time on the job: 6 hr (unchanged)
  • Filler wire price: 2.25 $ / lb (unchanged)

Working through the calculation

  • Applying the documented formula (Filler wire consumed = filler wire deposition rate × arc-on time on the job) to the inputs above produces each figure below.
  • At this operating point the engine returns 270 $ for total filler wire cost, the number this scenario is built around.
  • At this operating point the engine returns 120 units for filler wire consumed.
  • At this operating point the engine returns 6 hr for arc-on time on the job.
  • At this operating point the engine returns 2.25 $ / unit for filler wire price.

How this compares with the baseline

  • Against the tool's baseline example, where filler wire deposition rate sits at 8 lb / hr and the headline result is 108 $, this scenario comes in 150% above the baseline at 270 $.
  • A figure at this level is achievable when filler wire deposition rate is genuinely sustained, not just peaked for a shift. It uses deposited-weight economics and does not subtract spatter, stub loss or slag; add a deposition-efficiency factor (roughly 0.6-0.98 by process) for spool-purchased weight versus metal in the joint.

Results at a glance

  • Total filler wire cost: 270 $ (headline result)
  • Filler wire consumed: 120 units
  • Arc-on time on the job: 6 hr
  • Filler wire price: 2.25 $ / unit

Run it with your numbers

  • Every input above is editable in the live Filler Wire Cost calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.