Welding & Fabrication worked example
Filler Wire Cost with filler wire deposition rate of 4 lb / hr: a worked example
Suppose filler wire deposition rate falls to 4 lb / hr. This page works the full calculation at that level so you can see exactly which result moves and by how much. Estimate filler wire cost from deposition rate, arc-on hours, and wire price per pound.
The inputs for this scenario
- Filler wire deposition rate: 4 lb / hr (the input this scenario stresses; the baseline uses 8)
- Arc-on time on the job: 6 hr (held at the documented default)
- Filler wire price: 2.25 $ / lb (held at the documented default)
Working through the calculation
- The calculation starts from the formula this tool documents: Filler wire consumed = filler wire deposition rate × arc-on time on the job.
- Total filler wire cost works out to 54 $ at these inputs, and this is the headline figure for the scenario.
- Filler wire consumed works out to 24 units at these inputs.
- Arc-on time on the job works out to 6 hr at these inputs.
- Filler wire price works out to 2.25 $ / unit at these inputs.
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 50% below the baseline at 54 $.
- It multiplies deposition rate by arc-on time to get pounds of filler consumed, then multiplies by wire price to get total filler cost. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.
Results at a glance
- Total filler wire cost: 54 $ (headline result)
- Filler wire consumed: 24 units
- Arc-on time on the job: 6 hr
- Filler wire price: 2.25 $ / unit
Run it with your numbers
- To rerun this with your own numbers, open the live Filler Wire Cost calculator, set filler wire deposition rate to your actual value, and adjust the remaining inputs to match your operation.
Last reviewed 2026-05-12.