Welding & Fabrication worked example

Weld Deposition Rate at 99% deposition efficiency: a worked example

This scenario runs the weld deposition rate calculation on the strong side: 99% deposition efficiency, with every other input held at its documented default. Use it when you need an honest deposition rate per welder before quoting weld time, sizing filler purchases, or planning a multi-pass weldment.

The inputs for this scenario

  • Wire feed speed: 350 in / min (unchanged)
  • Wire weight factor: 0.03 lb / hr per in/min (unchanged)
  • Deposition efficiency: 99 % (raised for this scenario; the documented default is 95)

Working through the calculation

  • Applying the documented formula (Gross filler metal feed rate = wire feed speed × wire weight factor) to the inputs above produces each figure below.
  • At this operating point the engine returns 9.36 lb / hr for effective weld deposition rate, the number this scenario is built around.
  • At this operating point the engine returns 9.45 lb / hr for gross filler metal feed rate.
  • At this operating point the engine returns 0.09 lb / hr for spatter and stub end loss.
  • At this operating point the engine returns 99 % for deposition efficiency.

How this compares with the baseline

  • Against the tool's baseline example, where deposition efficiency sits at 95% and the headline result is 8.98 lb / hr, this scenario comes in 4.21% above the baseline at 9.36 lb / hr.
  • Use it when estimating weld time and consumable cost, comparing welding processes or wire diameters, or balancing a robotic or manual welding cell to a cycle time. Treat this as a target state: the delta against the baseline quantifies what the improvement is worth before you commit to chasing it.

Results at a glance

  • Effective weld deposition rate: 9.36 lb / hr (headline result)
  • Gross filler metal feed rate: 9.45 lb / hr
  • Spatter and stub end loss: 0.09 lb / hr
  • Deposition efficiency: 99 %

Run it with your numbers

  • Every input above is editable in the live Weld Deposition Rate calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.