Welding & Fabrication worked example

Weld Deposition Rate at 68% deposition efficiency: a worked example

This worked example runs the weld deposition rate numbers for a tougher week than the baseline: 68% deposition efficiency instead of the typical 95%. Estimate filler metal deposition rate from wire feed speed, wire weight factor, and deposition efficiency.

The inputs for this scenario

  • Wire feed speed: 350 in / min (held at the documented default)
  • Wire weight factor: 0.03 lb / hr per in/min (held at the documented default)
  • Deposition efficiency: 68 % (the input this scenario stresses; the baseline uses 95)

Working through the calculation

  • The calculation starts from the formula this tool documents: Gross filler metal feed rate = wire feed speed × wire weight factor.
  • Effective weld deposition rate works out to 6.43 lb / hr at these inputs, and this is the headline figure for the scenario.
  • Gross filler metal feed rate works out to 9.45 lb / hr at these inputs.
  • Spatter and stub end loss works out to 3.02 lb / hr at these inputs.
  • Deposition efficiency works out to 68 % at these inputs.

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 28.42% below the baseline at 6.43 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. A result at this level usually justifies acting on the stressed input before touching anything else, because every other figure in the table is downstream of it.

Results at a glance

  • Effective weld deposition rate: 6.43 lb / hr (headline result)
  • Gross filler metal feed rate: 9.45 lb / hr
  • Spatter and stub end loss: 3.02 lb / hr
  • Deposition efficiency: 68 %

Run it with your numbers

  • To rerun this with your own numbers, open the live Weld Deposition Rate calculator, set deposition efficiency to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.