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com

Welding Math (and some physics)

By Jerry Uttrachi

Understanding what causes a MIG wire to melt and what controls weld penetration
is very helpful in producing quality weld deposits and solving welding problems.
The relationship of gas pressure and volume is helpful in setting shielding gas flow and eliminating gas
waste. Bernoulli developed these gas equations in the 17 hundreds and Torricelli in the 1630’s
understood the basic properties of gases. The flow rates that cause turbulence in a MIG shielding gas
stream must be known and avoided for quality MIG shielding. Reynolds in the late 18 hundreds defined
the flow rate that produces turbulence. John Dalton in the early 18 hundreds defined that the pressure of
gas mixtures is an addition of the pressure of the individual gases. The implication for welding is if
shielding gas leaks from a hose or fitting, air and moisture are “flowing back through that same hole.”
When asked to make a 3/16 versus a 1/4 inch fillet weld fractions must be understood. Or if told the fillet
weld specification indicates a 5 mm size is needed, a conversion to US units may be necessary.
The information in the report is useful to welding students, welders wishing to advance to welding
technicians, welding robot operators, welding foremen, etc. It presents some welding math and physics
and discusses how to use the information. Most of these topics are on our web site or in PDF Downloads
available on our web site - in most cases, more detail is presented. Where this additional information is
available a web site link is provided so it may be readily accessed.
About the Author

Jerry Uttrachi is President of WA Technology, a company he founded in 1999 dedicated to helping companies
improve welding productivity and specializing in products and techniques to eliminate shielding gas waste.

Mr. Uttrachi started his career in the welding field over 40 year ago in welding R&D at the Linde Division of UCC, a
leading company developing welding shielding gases, equipment and filler metals. After managing the companies
Material Technology Laboratory developing welding shielding gases and filler metals he became Director of
Welding Market Development. When the welding division became a separate company he was named Vice
President of Marketing for the newly formed company, L-TEC. He was responsible for Business/Product
Management, Marketing, Customer/Technical Service, Special Customer Order Production, Training and
Communications. When the business was acquired by ESAB in 1989 he remained in that position for the L-TEC
brand and for ESAB’s Equipment business. In 1999 he left to form WA Technology.

Mr. Uttrachi is an active volunteer of The American Welding Society having served on numerous volunteer
committees including recently being on the AWS Board as Director at Large, three years as Vice President and the
2007 President of the 65,000 member Society. He currently is the Chairman of the Board of Trustees for the
Societies Education Foundation. He is also a member of ASME and is Chairman of his local Section.

Mr. Uttrachi has Bachelors degree in Mechanical Engineering, a Masters degree in Mechanical Engineering
(Emphasis Behavior of Metals) and a Masters degree in Engineering Management from the New Jersey Institute of
Technology. He has 10 patents in the welding field, with 5 issued in the past 7 year, 4 related to reducing shielding
gas waste and improving weld start quality. Mr. Uttrachi has published a number of welding articles in technical
trade publications and journals. He recently authored a 176-page book, entitled, “Advanced Automotive Welding,”
that was published in 2012. The book is referenced in the following text.

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Topics covered:

Topic Page What is Covered

A 2 Why Do We Need Math to Weld?
B 2 What Makes MIG Wire Melt?
C 3 Effect of Welding Current on Weld Penetration
D 4 Effect of Gas Pressure on Gas Volume
E 5 How to Read a Ruler (with information on working with fractions and
common metric conversions)
F 11 Calculate Shielding Gas Waste; (dealing with percentage)
G 14 Reynolds Laminar versus Turbulent Flow
H 15 Dalton Partial Pressure (gas leaking out of a shielding gas hose
means moisture laden air is flowing back in!)
I 16 Calculate Weld Volume
J 19 Calculate Weld Cooling Rate
Topic A: Why Do We Need Math?
To become a highly skilled welder it is desirable to understand some welding math and basic welding
physics. It is presented here in a way that doesn’t make it painful!
It Could Be Tougher: Imagine trying to do math in Roman Numerals! Actually addition is not a big
problem you just put all the letters together and rationalize extra letters denoting numbers; for example if
you have three V (5’s) they would be restated as XV for 10 and 5. However division is much more difficult
and a Roman “Calculator” called a ‘”Counting Board” is needed. Pebbles are placed in numbered boxes
etc. As for fractions, the Romans didn’t have a way to write them as numbers. They would state fractions
in words, for example as in the case of a ruler defining 3/16; “three of 16 parts.” In fact maybe they made
understanding fractions easier - they just said what they represented; “divide a unit in 16 parts and count
only 3 of them!” You can Google Roman Numeral math if interested.
Topic B: What Causes MIG Welding Wire to Melt?
Hint: this is what it is NOT; a) the “hot arc”, b) radiation from the arc or c) the wire passing through the
arc. Two phenomena are primarily responsible for wire melting:
1. The first reason is wire stickout. As the wire passes from the end of the MIG gun contact tip to
the arc, it is carrying all the welding current and becomes very hot. It starts at room temperature
and can exceed 500 degrees F before the arc forms at the end (depending on the "sickout," the
distance between the tip and the work piece.)
2. The second reason it melts is that current leaving or entering a surface, be it wire or hot puddle,
requires a given amount of energy for the electrons to enter or leave that surface. This energy,
generated at the surface, melts the already hot wire. Therefore assuming Electrode Positive this
is referred to as Anode Potential (also called Work Function and measures as voltage) and is
equal to the Amps x Anode Voltage.
The following equation obtained from Reference (1) page 3, defines the relationship:

2
Wire Melting Rate (lbs/hr) = a * Amps + b * Wire Stickout * Amps
Where "a" and "b" are constants and "Wire Stickout" is the distance from the torch contact tip to the work
piece measured in inches. (Note, constant b has been modified to compensate for the fact that this
equation was based on "Electrode Extension” that is measured to the top of the arc.)
The values for "a" and "b" for 0.035 inch diameter carbon steel wire are:
a = 0.017; b = 0.00014

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These two energy sources cause the wire to melt. The first term (a * Amps) is the anode voltage times
current and the second term defines the energy input due to resistance heating.
Topic C: EFFECT OF CURRENT ON PENETRATION
A major implication of the wire melting relationship is with increased stickout (at a fixed wire feed speed)
amperage will decrease. That has a significant effect on another parameter, weld penetration.
Weld penetration can be determined by a simple equation defined some years ago by C. E. Jackson in
Reference (2)
Weld Penetration (distance into the base material when making a weld on plate measured in inches) =
4 2 0.333
K [Amps / (Weld Travel Speed; ipm * Volts )]
For 0.035 inch diameter solid carbon steel wire, the constant K = 0.0019
Using these equations we find the following when we change wire stickout for 0.035 inch solid wire.
Assuming a fixed wire feed speed that produces 200 amps at 3/8 inch wire stickout:
Stickout, Amps Penetration % Loss in
inches inches Penetration
3/8 200 .127 base
1/2 184 .114 11%
5/8 172 .104 18%
3/4 162 .096 24%
7/8 154 .090 29%
Note:
1. With a fixed wire feed speed the amperage decreased from 200 amps with a 3/8 inch stickout to a
low of 154 amps when the stickout was increased to 7/8 inches. The resistance heating of the
2
wire (the 2nd Amp term in the equation) is a very efficient heating process. Therefore the
current needed to finish melting the wire as it enters the arc, becomes less as the wire is hotter
with longer stickout.
2. However there is a reduction in weld penetration when varying stickout in a normal range from
3/8 to 3/4 inches is 24%! If extended to 7/8 inches penetration decreases 29%.
Therefore it is very important to keep the torch stickout constant. Also the shorter the distance from tip to
work for a fixed wire feed speed the greater the penetration since current also increases. When welding
in the short circuiting mode it is often desirable to use a long contact tip which protrudes from the
shielding gas cup. This helps assure adequate penetration is maintained by keeping current higher. It
also helps visibility so the welder can stay on the leading edge of the weld puddle.

Weld Penetration Definition

For the purposes of this exercise, weld penetration is a measure of
how deep the weld penetrates in a bead-on-plate deposit. Have a
different wire than the 0.035 inch solid wire used in this example?
No problem. In fact not only changes in wire type and size but also
shielding gas and torch angle will alter the actual value. You can
generate your own constant K for what you are doing by making a
bead-on-plate deposit, cutting a cross section and etching it.
References:
th
1. AWS Welding Handbook, Volume 1, 9 Addition; pp 7
2. “The Science of Arc Welding” by C. E. Jackson. 1960 Welding Journal 39(4) pp 129-s thru 230-s

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The effect of welding parameter control, particularly wire “stickout,” from a MIG gun contact tip to the
workpiece and the resulting welding current change is very important to understand. The welding
operator controls the amount of “stickout” when semi-automatic welding and when moving the MIG gun
by hand. There are often locations where joint access does not allow the MIG gun nozzle room to
maintain a desired “stickout.” It must be understood that when “stickout” increases even though the
resulting weld bead may look good on the surface, the weld current reduced and the weld may have lack
of penetration into the base material. This is very important when operating in the “short circuiting” or
Short Arc” mode. This mode of metal transfer is commonly used when MIG welding out of position or
when welding thinner materials. When welding in this mode it is common to use MIG gun nozzles and
contact tip sizes that allow the tip to extend slightly beyond the nozzle opening.
What is Short Art Welding?
If welding with 0.035 inch diameter wire below 165 amps, or with 0.030 diameter wire at below 150 amps
the arc looks steady but is actually off for a percentage of the time. The welding wire is stubbing into the
puddle many times per second to reduce weld heat. It is a controlled stubbing with short circuit current
limited by the power source inductance and slope. The power supply design is a reason some welding
machines perform better compared to others, especially in the “Short Arc’ mode of metal transfer.
The picture left presents schematically what is
occurring while “Short Arc” welding. It is one of 450
pictures in our recently published book, “Advanced
Automotive Welding” that covers the three modes of
MIG welding, Spray Arc, Short Arc and Pulsed Arc.
It discusses in detail all welding (and cutting)
processes; Oxyacetylene, TIG, Stick and MIG
welding. It also presents information on Oxyfuel
cutting, Plasma cutting, and an overview of Laser
and Water Jet cutting processes. It includes an
overview of welding safety.
In addition to presenting, the math related to wire
deposition rate or burn-off rate it has
photomicrographs of the effects of changing
welding “stickout,” volts, and travel speed on
weld penetration. The photomicrograph right is
one shown in the book. It displays the effect of
changing “stickout” on weld penetration. There
are also photomicrographs of the effects of other
variables on penetration presented, such as MIG
gun angle relative to the workpiece.
The book is available for purchase at:
http://www.netwelding.com/prod02.htm#Book
It is an excellent book for use by welding
students, presenting formal welding process
information, some welding science and
metallurgy and many practical applications and project examples. The projects and applications relate to
welding cars, street rods and racecars. It discusses the welding of carbon steel, chrome-moly steel,
stainless steel and aluminum. It also presents an overview of welding titanium and magnesium. There
are 450 colored pictures, which have detailed captions, making the book easy and fun to read. It includes
an extensive Glossary and is an excellent welding reference. It is also useful for welders with experience
who want to understand the benefits of modern welding equipment and process variations such as
Pulsed MIG welding. Examples are presented showing where Pulsed MIG welds can be made to look
similar to TIG welds with excellent shape and without spatter. The welding an aluminum Corvette frame
reviews why GM specifies the use of Pulsed MIG welding for this application.

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Topic D: Gas Pressure / Volume Calculations

Understanding the relationship between gas pressure and volume will help
when setting gas flow and understanding MIG shielding gas use and waste.
In 1662 Robert Boyle defined the basic relationship between Gas Pressure and
Volume. He stated the relationship in mathematic terms as:
P1 / P2 = V1 / V2 (Where P, pressure, is measured as absolute pressure =
gauge pressure + 14.7 psi at sea level)
For example, in a MIG gas delivery hose if the initial absolute pressure is
doubled the gas volume must be double. That was until 140 years later when
around 1800 both Charles and Dalton independently added temperature to the
relationship! They defined the following relationship:
V1 / V2 = T1 / T2 (Where T, Temperature is measured as absolute
Temperature in degrees Rankin = Degrees Fahrenheit gauge + 460)
Applying this equation, we'll see in general we need not worry about temperature effecting volume in
normal ranges:
i.e. V1 / V2 =T1 / T2
If T1=75 F than T1Rankin = 75+460=535 R
Assume T2 = T1 + 20% =90 deg F; then T2 Rankin = 90+460=550 R
V1/V2 due to 20 % Temp Difference =
V1 / V2 =T1 / T2= 535/550=0.97
Alternatively, at a constant pressure, an increase in Temperature of 20% measured in degrees
Fahrenheit yields only 3% increase in volume. For most welding purposes and over the range of
production temperatures there is not enough change in Volume with gas Temperature to consider it
significant.
The general Gas Laws can be written as:

(P1 * V1) / T1 = (P2 * V2 ) / T2

It can also be written as P * V = (nR) T

where the constants nR can defined based on the gas. We'll let you find details about the nR by
searching the Internet since for our purposes ratio comparisons are all we need.
MIG WELDING EXAMPLE
Assume:
1. The pressure needed in the gas delivery hose from gas source to welder/feeder to flow 30 CFH is
3 psi.
2. A regulator/flowmeter is used that employs an 80-psi regulator.
Therefore, when welding stops gas continues to flow through the needle valve flow control (or orifice flow
control) until the pressure in the gas delivery hose equals 80 psi.
Then the volume of excess gas in the gas delivery hose compared to the volume when welding will be:
V stopped / V welding = P stopped / P welding =
(80 psi +15) / (3 psi + 15) = 5.3 times the physical hose volume
Hose Expansion Causes More Excess Volume: Tests of a standard 1/4 inch diameter gas delivery hose
showed it had a 13% increased volume due to the hose expanding with 80-psi pressure. Therefore 87%
of the excess gas stored in the hose is due to the increased Pressure and 13% of the excess due to Hose
Expansion.
3. Excess Gas Blasts Out of the MIG Torch When Welding Starts: The high velocity
creates turbulence in the shielding gas stream, which takes several seconds to stabilize to a
desirable smooth Laminar flow. The turbulence pulls in air causing excess spatter and internal
weld porosity. For a typical 5/8 inch diameter MIG nozzle more than 50 CFH flow rate causes
this turbulent flow. For a smaller 1/2 inch diameter, nozzle flow rates should not exceed about
40 CFH.

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Topic E: How To Read A Ruler (Includes Basics of Fractions and Common Metric Conversions)

Reading a ruler in US Units requires working with Fractions. If the Metric System was
being used it would not be needed- but more on Metric below.
Rulers and measuring tapes are commonly calibrated in feet and inches. Instead of
segmenting the foot into 10ths of a foot, it is divided into 12
parts labeled inches.
The inch is commonly split into 8, 16 or sometimes 32 parts.
Therefore working with fractions is a necessity. A fraction of
an inch is a mathematical way of showing the number of the
parts into which it is divided. For example, 3/8 inches is a
way of showing a measure of 3 of the 8 parts into which it
was divided. The picture left is an example of an inch split
into 8 parts or eighths. The yellow arrow is pointing to the
third line from the start or the 3rd of 8 parts stated as 3/8. It’s shown with a division line
because we could divide 3 by 8 and get 0.375 the decimal value. Now if the number of
segments and the total number of segments into which the inch mark was split were
always stated, fractions would be relatively easy-but it is not that easy!

SIDE BAR: Why is Time and US Measurement Broken Into 12’s Instead of 10’s?
The Egyptians were responsible for the 24-hour day. The Egyptians were fond of counting in base twelve (instead of base
10, which is commonly used today). This is thought to be because they counted finger joints instead of fingers. Each of
finger has three joints, so if you count by pointing to finger joints with your thumb you can count to twelve on each
hand. This seems arbitrary, but is actually just a strange as counting in base ten simply because we have ten digits!

The example, the picture on the right shows the 4th of the 1/8
inch marks in red. Since 4 is 1/2 the way to 8, it is the 1/2 inch
mark. We could have said 4/8 which is the same as saying 1/2 .
It is usually desired to display the fraction by having the lowest
whole number at the bottom.
If the bottom number (called the denominator) can be divided by the number on top
(called the numerator) and a whole number is the result - the fraction would have the
lowest number possible in the denominator.
Looking at the picture left and counting from the start or zero
mark there are 6 spaces or 6/8 of an inch. Dividing 8 by 6
produces 1.333 which is NOT a whole number (one with no
decimal left over.) However both numbers can be made
smaller. Any number or fraction can be multiplied or divided
by 1 without changing its value. This can be accomplished
by multiplying or dividing both the numerator and
denominator by the same number. Both the numerator and
denominator could be multiplied by 2 (actually 2/2) that would give 6 * 2= 12 for a

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numerator and 8 * 2 or 16 for the denominator. The fraction would become 12/16. That
would be accurate and a person could be told to go cut a steel rod 12/16 of an inch
long. However the objective is to have the smallest numbers. Both numerator and
denominator could be divided by 2. That would give 6/2 = 3 for a numerator and 8/2=4
for a denominator. The fraction now becomes 3/4. It is the same value as 6/8 but with
smaller numbers. Notice on the ruler there are some lines longer than others. In this
case the longest lines are quarters of an inch rather than eighths. Three of these
longest lines could have been counted and it would be found more quickly as the third
quarter or the 3/4 mark!

However we must have common numbers in the denominator (bottom numbers) if two
dimensions are to be added. Suppose two items are to be measured and a total length
presented. If one is 3/4 inches and the other 3/8 inches
what is the total length? Quarters and eights can not be
added directly. It is best to convert all measurements to
the largest denominator. Therefore 3/4 becomes 6/8
(remember the numerator and denominator can always
be multiplied by the same number which is really
multiplying the fraction by 1.) The result is 6/8 + 3/8.
The picture left shows the answer graphically. But let’s
get the answer using math. To add fractions 6 of the
eight parts are being added to 3 of the eight parts. So only add the numerator values
(top numbers.) Therefore 6 + 3 = 9 or 9 eights. Stated as a fraction, 9/8. Whenever the
numerator is bigger than the denominator the numerator can be divided by the
denominator to change to a whole number and possibly a fraction remainder. In this
case, 8 goes into 9 once with one left over or 8/8 + 1/8 or 1 1/8 inches. This mark can
be seen on the ruler as one space after 1 inch. There would be nothing wrong with
saying the answer was 9/8 but suppose the result was 13 inches and 3/8 inches. It
could be stated as 13 * 8 or 104/8 + 3/8 or 104 + 3 = 107/8. However if it was
necessary to measure using that dimension it would be a lot of 1/8’s for someone to
count!

A 1 inch ruler mark could also be split into 16 segments. This is a

common way to make a ruler or tape. These smaller marks are
still easy to read (compared to splitting it into 32 parts as is done
with some steel rulers.) The picture left shows this segmentation
with the 1/8 inch marks and the 1/4 inch marks shown as longer
red lines. The 1/16 inch marks shown in black are the shortest. This makes it easier to
read quickly.

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A tape measure is the same as a

ruler except it is longer and flexible.
There are also some interesting
things to note about most metal
tapes. The picture left is a magnified
section of a ruler. This ruler is
segmented into 1/16ths or 16
segments in an inch. It is also
labeled in feet as well as inches. If a
measurement is to be made to the yellow arrow it
is located at the 12 inch or 1 foot mark plus 3
spaces. therefore there are 12 inches and 3/16
inches from the end of the ruler to the yellow
mark. The mark is said to be 12 and 3/16 inches
or 1 foot 3/16 inches-both would be correct.
There are a few other things that should be
understood
about a tape
measure:
As seen in the picture above there is a metal tab at
the start end of the tape. It is usually attached with
two rivets. However it is loose. Do Not tighten these
rivets with a hammer! The tab is loose for a reason.
If you’re making what is known as an “inside”
measurement (picture left) after the tape is locked in
position (with black button on top) the tape is pushed
with a slight force into the part to be
measured. The tab moves in toward the
ruler and provides an accurate
measurement by properly positioning
the zero location.
In the photo right the tape is being used
to measure from the outside edge of an
item.
The tape is pulled slightly away from the
edge being measured and the tab
moves slightly to the left in this case. It
moves the thickness of the tab so that

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the zero point is now on the inside or from the photo the right side of the tab. This
places the zero location as necessary to have it measure properly.

Another item that is often included on most tape measures is the exact width of the tape
holder and it is printed on the side of the body. In the picture above it is shown as 3
inches. (it is also shown as 76 mm which is the approximate metric equivalent.) If the
distance between a door jam was to be measured, for example, the tape could be
placed in the space, pushing the end slightly into one door jam as defined above to
have the tab properly positioned. The back of the tape holder is placed against the
other side of the door jam. The tape could be read at the front (see “Read Tape Here”
in above picture) and in this case add 3 inches to account for the tape holders body
size. So if 33 and 9/16 inches was read then the actual dimension would be 33 + 3
added so the final dimension would be 36 and 9/16 inches. Now if the ruler was only 2
1/2 inches wide then the actual dimension would be 33 and 9/16 plus 2 1/2 inches. The
whole inch measurements could be added, therefore 33 + 2=35. However to add 9/16
to 1/2 requires stating the 1/2 as 8/16 inches. Then 9/16 + 8/16= 17/16. Since the
numerator is larger than the denominator we can divide the numerator by the
denominator and obtain 1 with 1/16 left over. Then the final dimension is stated as
33+2+1 and 1/16 or 36 and 1/16 inches or dividing 36 inches by 12 in/ft =
3 feet 1/16 inches.

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Metric:
Metric Units (now called SI for international Standard)
are used by about every country accept the US. Many
items such as cars and trucks made and purchased in
the US today use SI dimensions, bolts etc!
Metric is actually a simpler system and does not use
fractions! All units are in 10ths. The basic length
measure is the meter (slightly longer that a yard.) The
preferred unit smaller than a meter is a 1000th of a
meter called a millimeter (the abbreviation is mm.)
100rdth of a meter is called a centimeter (abbreviated
as cm). A cm = 10 mm's. Everything is expressed in
10ths or multiples of 10. The ruler in the above left
picture is dual dimensioned; it shows inches on top and
metric on the bottom. The top is segmented in 1/16th of an inch with the number of
inches displayed. The metric is labeled centimeters with segments in millimeters.

This picture shows a conversion

from 20 inches to metric. The
ruler has both US Units and
metric units. As noted,
20 inches must be multiplied by
the conversion factor of 1 inch =
25.4 mm. Therefore 20 inches
= 508 mm. Then 508 mm
divided by 10 mm/cm = 50.8.
Note all we have to do to divide
by 10 is move the decimal over
1 place. That yields 50.8. Or
50 cm and 0.8 cm. But a cm is
10 mm. So it could be written
as 50.8 cm or 50 cm + 8 mm.

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Below Are Some Common Welding Metric Conversions

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Topic F: Calculate Shielding Gas Waste

The table below provides a way to estimate MIG shielding gas waste. The data needed
can be obtained from purchasing or your supplier of wire and shielding gas.
Use purchases over a period of 6 months to a year to avoid
introducing errors due to variable amounts of inventory.
Notes: 1) If you’re using CO2 it probably is purchased in pounds.
You'll need cubic feet (CF) in the calculations; there are 8.74 CF per
pound of CO2; 2) Argon is usually sold in CF or in 100 CF- if you
are purchasing Argon in Liquid form you may be purchasing it in
gallons. If so there are 113 CF of Argon gas when measured at 70
deg F and 1 atmosphere in each liquid gallon; 3) If the welding wire purchase records
are only kept in dollars, you'll need the cost per pound. If needed, ask your supplier,
they keep the data in a form that you can use directly.
TYPICAL SHIELDING GAS TO WIRE PURCHASE RATIO
Wire Size Typical CF Gas/ 1 lb
Type Lbs/hr Wire
Purchased
Solid .035 3.5 10 CF

Solid .045 7.0 5.0 CF

Cored .035 6.5 5.5 CF

Cored .045 7.5 5.0 CF

Cored 1/16 11.0 3.5 CF

Cored 3/32 14.5 2.5 CF

Compare the typical values in the above table with your usage.
Example: You purchased 46,000 lbs of 0.045 solid wire in the past 6 months and during the same
period 610,000 CF of Argon and CO2 combined:
1. Multiple the value from the far right column in the above table times the wire purchase
amount; 5.0 CF/ 1 pound X 46,000 lb of wire purchased = 230,000 CF of gas you should
have purchased.
2. But you purchased 610,000 CF of gas. Therefore 610,000 – 230,000 = 380,000 CF was
wasted or 380,000 Wasted / 610,000 Purchased = 62% Gas Wasted!
If you use several types of wire, treat each individually and add the total gas requirements.

See more Information at: http://netwelding.com/Simplified_Gas_Waste_Estimate.htm

Dealing With Percentages:

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Reviewing a fabricators test measurement of Gas Flow and Savings when using our
patented Gas Saver System shows ways to deal with percentages:

Texas Truck Storage Box Manufacturer Welds 2.7 Times More Parts with Gas
Saver System; a 63% Gas Savings
A Texas based manufacturer of various types of truck storage
boxes purchased one of our patented 25 foot Gas Saver
Systems (GSS) (WAT- FB25) to check for shielding gas
savings. They picked a repetitive job, welding doors, and
started with a full cylinder of gas. Welding with 0.035 solid wire
MIG, using their standard gas delivery hose, 236 doors were
completed with that cylinder. Putting on a new cylinder and the
GSS, with no other changes, 632 doors were welded before the
cylinder was empty! That is 632/236 = 2.7 times more parts.
The gas savings can be stated several ways. In the base test, with the normal gas
delivery hose, 300 CF of gas was consumed welding 236 parts. With the GSS they
consumed only 300 CF x 236/632 = 112 CF for that same number of parts. Therefore
300 CF - 112 CF = 188 CF is wasted with their normal system! And the GSS still
provides the proper amount of extra gas at the weld start and maintains the pressure in
the hose to automatically compensate for restrictions.
Calculating the gas savings as a percentage of prior use; (300 -112)/300 = 63% gas
savings. Or said another way it takes 300/112 = 268% more gas to weld the same
number of parts. After these impressive results, 25 GSS's were purchased for the
whole shop.
Stated another way; to weld 632 doors with their
standard system they would have needed 2.7
cylinders versus only one with the GSS !!

After several years of use they needed another 10

GSS's for new MIG welders. They asked for more
"Magic Hose!"
Note, there are a number of ways to use Percentage. Just be sure they are stated
correctly, i.e. the same numbers yielded 268% more or 63% less etc. The same data
can be presented both ways.

See More Examples of Reported Gas Savings with our Patented Gas Saver System:
http://netwelding.com/production_test_results.htm

Welding School

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Welding schools can save a great deal of

wasted MIG shielding gas by using our
patented Shielding Gas Saver System (GSS.)
Picture shows welding instructor, Sue, holding
25 GSS ready for installation at Florence
Darlington Technical College.
The reasons for a great deal of gas waste in
schools are many tack welds and short welds
are made. In addition students often inch the
wire to cut off the end to get a good arc strike.
Even when just inching the wire to cut off the
end here is the sequence of what happens to
the shielding gas supply system that creates a great deal of gas waste.
Assume a common regulator/flowgauge is being used to
set shielding gas flow (picture right.) When welding, the
gas pressure in the gas delivery hose from
regulator/flowmeter to welder will have about 4 psi. When
welding stops the gas solenoid in the welder or wire feeder
closes and the pressure in the hose will quickly rise to the
regulator pressure often about 60 psi for normal flow rates.
This stores excess gas to be stored in the hose. How
much? The amount of gas stored is proportional to the
absolute pressure or 60 psi+15 psi = 75 psia (absolute.)
When welding it will be 4 psi+15 psi= 19 psia. Therefore the excess is 75 psia/19 psia
or about 4 times what is needed. Most of this excess blasts out of the MIG Gun Nozzle
when welding starts or even when just inching the wire to cut off the end. Short welds
and tack welds common in schools make the waste situation very high. The blast of
gas also affects the weld start quality since air is pulled into the shielding gas stream
causing excess spatter and possible internal weld porosity
See more information about what can be done to reduce gas waste in schools at:
http://netwelding.com/Weld_School.htm

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Topic G: Laminar versus Turbulent Shielding Gas Flow

High gas flow surge at a MIG weld start causes turbulence in the shielding gas stream. This
turbulence causes air to be mixed into the shielding gas stream until the flow rate stabilizes to
the preset level. The entrained air causes excess weld spatter and can cause internal weld
porosity
The maximum desirable flow rate was published by The Welding Institute (TWI) in
England [Wilkinson, M. E., Direct Gas Shield Analysis to Determine Shielding Efficiency.
Report of The Welding Institute, Cambridge, England] The exact transition will be
dependent on the type of torch used as well as other variables however this study
provides some perspective and cautions on the use of too high a flow
rate.
In an 1893 technical paper Osborne Reynolds defined in tests there was a very
well defined flow level below which a smooth "Laminar" flow was achieved.
Beyond that level a more chaotic "Turbulent" flow exited. He also defined that it
takes a short period of time for the gas flow to become smooth and Laminar if
it starts in a Turbulent mode. Therefore at a weld start, the high velocity surge
of shielding gas exiting a MIG torch is Turbulent and will take some time to reach the Laminar
flow that is needed to eliminate air from the shielding gas stream. Photo left is a schematic of
Osborne Reynolds standing next to his flow testing apparatus.

The graph above defines the maximum flow for several common size MIG Gun Nozzles
beyond which undesirable Turbulent Flow exists. Not these flows are not much higher
than those recommended and unfortunately below where some welders believe they
can set shielding gas flow.

More Information can be found at: www.netwelding.com/sales_literature.htm

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Topic H: A Shielding Gas Leak Means Air is Leaking Back!

A phenomenon called the law of partial pressures was

developed by John Dalton (Born 1766). He found that a
mixture of gases behaves as if each were separate. Dalton’s
Gas Law: He observed that the Total Pressure of a Gas
Mixture was the sum of the Partial Pressure of each gas.

P total = P1 + P2 + P3 + .......Pn

The Partial Pressure is defined as the pressure of a single gas

in the mixture as if that gas alone occupied the container. In
other words, Dalton maintained that since there was an
enormous amount of space between the gas molecules within
the mixture that the gas molecules did not have any influence on the motion of other
gas molecules, therefore the pressure of a gas sample would be the same whether it
was the only gas in the container or if it were among other gases.

Since there is no Nitrogen in a shielding gas hose the partial pressure of Nitrogen in the
hose is 0. Since there is 78% Nitrogen in the surrounding air, the partial pressure of
Nitrogen is 14.7 psia x .78 =11.5 psia. Therefore there is a driving force for the Nitrogen
to reach equilibrium of 11.5 psia into the hose leak! It will not move as fast as the Argon
coming out which may have a driving force of say 25 psig + 14.7 psi = 39.7 psia versus
0.009 x 14.7= 0.13 in the air. Or a driving force of 39.6 psia which is 3.4 times as much
but very little Nitrogen in the gas stream is needed to cause problems.

If welding a material needing a low hydrogen deposit is being used and leaks are
present in gas lines, hoses or fittings hydrogen from moisture laden air is entering back
though those leaks!

Another way to think about Oxygen, Nitrogen or water vapor going back through the
hole in our gas delivery hose where an Argon or CO2 based shielding gas is leaking out
is to consider Dalton’s statement.

“The gas molecules are spread far apart. The Oxygen, Nitrogen or H2O vapor will not
likely hit an Argon or CO2 molecule on its journey through the hole! To provide a picture
of how far apart say Argon atoms are at atmospheric pressure as they escape from a
leak consider: The density of Argon at room temperature and atmospheric pressure is
787 times less than liquid Argon. Therefore the spacing between Argon atoms in the
gas is 787 times larger than in Argon Liquid! Pretty far apart!

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Topic I: Calculate Weld Metal Volume (and other formula)

You Can Start From Basics and Calculate Any Weld Volume.
First some formula to calculate Area:
The basic formula for the Area of Rectangle is:
L (length) * W (width) = Area (Note: We'll use * to indicate
multiply since that is what is used on a Spreadsheet.)
Here is a neat way to check your answer called Dimensional
Analysis. Big word but it means checking the dimensions to be
sure the result is what you are looking for and helps to be sure
your formula is correct:
In this case: L inches * W inches = Area inch2 (Since in * in =
in 2 )
Dimensional Analysis verifies you correctly multiplied in * in and got in2

Note: a Square is a special case of a rectangle where both

sides are the same so the area can be stated as one side
times itself or Area = S2 (Length of a side squared)

Let's now define the Volume of a Rectangular Block.

W in * L in * D (Depth) in = Volume in 3
We multiplied three dimensions in inches so got in 3 or cubic
inches as an answer.

The following are some formula for calculating the area of

additional shapes we’ll use to define weld volume in a joint:
For the Triangle on the right: Area = B * H / 2
Note it is like calculating the Area of a Rectangle and dividing
by 2.
This formula works for any size and shape Triangle. Look at
the Triangle below left. Below right are picture examples that
help show why this equation
works for any shape Triangle:
By duplicating the Blue
Triangle and rearranging
pieces we can construct a
rectangle:
Referring to the three pictures
on the right:
1) In the top picture the Blue

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Triangle is copied and turned upside down It is shown in Green.

2) In the middle picture we make a small Red Triangle to create a straight
perpendicular side on the Blue Triangle.
3) In the bottom picture the Red Triangle is moved to the left side making a straight
side on the Green Triangle.
4) That makes a Rectangle with one side still equal to B and the other H.
5) The AREA as defined for a Rectangle is B * H. But remember we duplicated the
Blue Triangle so to get the AREA of the Original Blue Triangle we have to divide by 2
hence the formula: Area = B * H / 2
Area of a Segment (Weld Reinforcement)
This is one Area that is often used in calculating weld metal
area and volume; it is called the area of a Circle Segment
and shown in Red on the photo left. This is what is used to
calculate the area of Weld Reinforcement. The accurate
way to do this is to calculate the area of a segment of Radius
R (that is the combined Green and Red Areas;) use the
length of the Cord W (width of weld) and subtract the area of
the triangle formed by the Cord and distance from the
Center of the Circle and the Cord (the Green Area.) This
leaves the Area between the Cord and the Outer Area of
the Circle (Red Area) or Weld Reinforcement in our case.
However we would have to estimate the Radius of the circle making the reinforcement
and the angle of that Segment. Not an easy item to estimate. Since we know the weld
bead height (or the desired maximum height by code, usually 3/32 or 1/8 inch) and the
weld height is much smaller than the weld width we can use a method that estimates
the area and is probably better than estimating the radius. The formula is:
Approximate Area of a Segment (Weld Reinforcement) = (2 H * W) / 3 + H 2 / 2W
Since weld reinforcement is not a perfect circle, the value obtained is sufficiently
accurate for any engineering calculations needed. In fact since weld reinforcement is
not a portion of a perfect circle this approach may be closer to the actual area/volume!
Having checked several typical weld reinforcements dimensions you can use
72% of the Area of a Rectangle for the estimate of reinforcement.

With these basic shapes you can calculate the area of

almost all welds.
Look at the following examples of the of weld joints; the weld
area can be arranged into Triangles, Rectangles and
Segments.
To calculate the weld metal volume that must be added to a weld
joint you simply multiply the Area times the Length in the same
dimensions. Therefore if the length is given in feet convert it to
inches so all dimensions are in inches. Therefore Area in2 *

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Length in = Volume in3. Remember dimensional analysis works to check your work
in 2 * in = in3.

Calculate Pounds of Welding Materials Needed:

Now the Volume of weld metal you’ll need to add is known , how much wire will you
need? The following are some material densities:
Steel weights: 0.284 lb / in3; Aluminum = 0.098 lb / in3 depending somewhat on alloy
and Stainless Steel 0.29 lb / in3 again depending on the alloy.

So to get lbs of weld metal needed do you just multiply the volume by the density
of the material?
Is that how much you should purchase?
No! You Must Account for Losses.
For example when Stick Welding the electrode purchased includes flux, you’ll also
throw away the stub and some of what you’re depositing will become wasted spatter.
The factor that estimates the amount of welding electrode purchased that deposits as
weld metal is called Deposition Efficiency. Stick Electrodes, as you’d expect, have
the lowest values. Depending on the length, type of electrode and the amount of stub
being thrown away the Deposition Efficiency can vary from as low as 40%, meaning
only 40% of what you purchase will become weld metal to a high of 60%. For general
calculations you can use 50%.
The following are some values you can use for various welding processes:
Submerged Arc Welding = 99% for wire
MIG Welding with Solid Wire = 97% with Argon Based Shielding and 96% with CO2
MIG Welding with Metal Cored Wire = 94%
Gas Shielded Flux Cored Wire Welding = 90 to 93%
Self Shielded (Gasless) Flux Cored Wire Welding = 78 to 80%
Stick Electrode Welding = ~50% +/- 10%
Therefore divide the weld metal needed by the Deposition Efficiency (as a decimal,
i.e. 93% = 0.93) to get how much of the particular filler material being used needs to be
purchased.

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Topic J: Weld Cooling Rate

This Topic provides the math equations

that estimate the theoretical cooling rates
for TIG welds.
The data is presented so one can see the
numbers and dimensions from each part
of the equation. TIG process efficiency is
shown at 0.57 (57%.)

Equation Elements and Values

Rc = Cooling rate at weld centerline;
deg F/min
k = Thermal Conductivity of metal;
BTU/min in deg F
p = Density of metal; lb/in3
C = Specific Heat of metal; BTU/ (lb
deg F)
h = thickness of metal; in
Hnet = Net heat input = BTU / in [V * I / ipm * 0.57process efficiency for TIG]
Tc = Temperature which cooling rate is calculated; deg F
To = Initial plate temperature; deg F
Welding Cooling Equations from pp 100 Welding Handbook Volume 1, 9th Edition
Thick Plate Equation =Rc = - [2 * 3.1416 * k(Tc-To)2] /Hnet

Thin Plate Equation = Rc = 2 * 3.1416 * kpC (h/Hnet)2(Tc-To)3

Calculate estimated cooling rate @ 1100 deg F for thin wall 4130 tube welds:
Tube = .040 in wall; V (volts) = 10; I (amps) = 70; travel = 12 ipm
Using thin plate equation:
Rc = -2 * 3.1416 * 0.024 * 0.29 * 0.11= - 0.00481
Hnet = 1.66
(h / Hnet)2 = 0.000579
(Tc-To)3 = 1.07 * 109
Rc = -2981 deg F / min = - 50 deg F / sec

More Examples for 0.0625 and 0.093 inch wall and references are at:
http://netwelding.com/4130_Math.htm

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