Fixtra

Welding Consumable Cost Calculator

Deposited weld metal, filler required (accounting for deposition efficiency loss), shielding gas and SAW flux — costed per joint and per assembly. This covers consumables only; labour is the separate Total Welding Cost tool.

1 Joint & geometry

Joint type

Fillet leg size mm

Plate thickness mm

Pipe OD mm

Wall thickness mm

Included groove angle deg

Root opening (gap) mm

Root face (land) mm

Weld length mm

Reinforcement / convexity factor

Material

Identical joints per assembly

2 Process & consumable prices

Process

Deposition efficiency

Deposition rate kg/hr

Filler price $/kg

Uses shielding gas?

Gas flow L/min

Gas price $/m³

Flux : wire ratio (SAW)

Flux price $/kg

Currency symbol

Deposited weld metalactual metal in the joint—

Filler metal requireddeposited ÷ efficiency — what you buy—

Weld length used—

Filler cost—

Shielding gas cost—

Flux cost (SAW)—

Consumable cost — per joint—

Consumable cost — per assembly—

Cost per unit length of weld—

What this does & the assumptions it makes. Deposited weld metal = weld cross-section × length × material density. Cross-sections used: fillet (leg²/2)×reinf; single-V (gap·t + (t−face)²·tan(angle/2))×reinf; double-V uses half the bevel fill; pipe uses the single-V section around π×(OD−wall). Filler required = deposited ÷ deposition efficiency — you always buy more than you deposit (stub loss, spatter, slag). Gas is billed on arc-on time = deposited ÷ deposition rate, so the deposition rate you enter affects gas cost. Process defaults (efficiency, deposition rate, gas flow) are typical mid-range values you can and should override with your own shop data — they are not authoritative. Prices are whatever you enter, in your own currency. This is a cost estimate for planning, not a quotation, and it excludes labour, power, equipment and overhead (labour is usually the larger cost — see the Total Welding Cost tool).