Welding & Fabrication Math: Weld Volume, Filler Metal, Heat Input & Cutting Layouts
Weigh plates and bar from dimensions and density, calculate fillet and groove weld areas, weld metal volume and deposited weight, filler metal with deposition efficiency, heat input in kJ/in with a WPS check, arc time and cost per joint, saw cut lists with kerf and remnants, and a full job cost with a chart: 8 graded labs for welders, fabricators and estimators. Illustrative values; follow the applicable welding code and safety rules. Not affiliated with any welding society.
The first lesson is free — no account needed.
About this course
A welding and fabrication math course that estimates the jobs of one fictional fabrication shop, Redforge Fabrication, in a spreadsheet, for welders, fabricators, welding students, estimators and shop supervisors. You weigh plates and round bar from dimensions and density in pounds and kilograms, calculate the cross-section of fillet and single-V groove welds and the effective throat, turn weld areas and lengths into weld metal volume and deposited weight, buy filler metal with the deposition efficiency of each process, calculate heat input in kJ/in from volts, amps and travel speed and check it against an illustrative WPS range, estimate arc time and welding cost per pound, plan saw cuts from 20 ft bars with kerf and remnants, and cost a complete job with a chart. Illustrative values: follow the applicable welding code, the WPS and safety rules, with no affiliation with any welding society. The first lab is free.
Lessons
- Metal Weights from Dimensions & Density: Plates, Round Bar, lb & kgFree
- Weld Cross-Section Area: Fillet Triangles, Throat & Single-V Grooves Pro
- Weld Metal Volume & Deposited Weight: in³, lb per Foot & Job Total Pro
- Filler Metal to Buy: Deposition Efficiency, Packages & Cost Pro
- Heat Input: Travel Speed, kJ/in = V × A × 60 ÷ (1000 × Speed) & a WPS Check (Chart) Pro
- Welding Time & Arc-On Cost: Deposition Rate, Operating Factor & Cost per lb Pro
- Cutting List & Bar Nesting: Pieces per Bar with Kerf, Bars, Remnants & Utilization Pro
- Fabrication Job Costing: Labour, Gas, Filler, Consumables & Overhead (Chart) Pro