Weld Dilution
Compute a weld's dilution, D = (melted base-metal area / total bead area)·100%, the proportion of the bead that came from the base metal rather than the filler. It is crucial in cladding and dissimilar-metal joints: high dilution mixes in more base metal, altering the bead's composition and properties (anti-corrosion cladding aims for low dilution). Enter the melted base-metal area and the total bead area.
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Weld dilution
When you weld, the arc melts not only the filler metal (the consumable) but also part of the base metal of the workpiece — and the two mix in the weld pool. Dilution D = (melted base metal area/total bead area)·100% measures that mixing. Keeping it under control is critical in two situations. In corrosion- or wear-resistant cladding, you want low dilution (10–15%): the aim is to deposit the pure high-alloy layer on the surface, without 'contaminating' it with the base steel underneath. In the joining of dissimilar metals, dilution sets the final composition of the bead and decides whether it will turn out brittle or tough — welding stainless steel to carbon steel, for instance, means calculating the dilution to pick a consumable that yields a sound microstructure (using diagrams such as the Schaeffler diagram). Enter the melted base metal area and the total bead area.
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Weld Deposition Rate
Compute a weld's deposition rate by dividing the mass of deposited metal by the arc-on time, giving kg/h. It is a central indicator of process productivity: processes like submerged arc and MIG/MAG have far higher rates than stick electrode. Combined with the operating factor (actual arc time), it estimates a joint's output. Enter the deposited mass and the arc time.
Metallostatic Pressure
Calculate the metallostatic pressure exerted by molten metal at the bottom of a mold, P = ρ × g × h, from the molten metal density ρ (kg/m³), gravity g and the metal column height h (m). The result, in pascals, is the pressure the molten metal exerts on the mold walls and bottom due to its own weight — analogous to hydrostatic pressure, but with the high density of metals. It is essential to size the mold strength (which can 'burst' or deform under pressure), predict core flotation and metal penetration into gaps. Dense metals (iron, ~7000 kg/m³) generate high pressures. Enter the metal density and the column height.
Electrode Consumption
Estimate the number of electrodes needed for a weld by dividing the total mass of metal to deposit by the mass deposited per electrode (rounding up). It is a practical planning and budgeting calculation in stick-electrode welding, avoiding over-buying or stopping the job for lack of consumables. Enter the total weld mass and the mass deposited per electrode.
Welding Heat Input
Compute the heat input of a weld, H = (V·I·60)/(v·1000), in kJ/mm, from the arc voltage (V), the current (I) and the travel speed (v, in mm/min). It is one of the most important welding parameters: it controls the cooling rate, the microstructure, the heat-affected-zone hardness and the cracking risk. High input softens and distorts; low input hardens and embrittles. Enter the voltage, the current and the travel speed.
Welding Preheat Temperature
Estimate the preheat temperature for welding, Tp = 350·√(CE − 0.25), as a function of the steel's carbon equivalent (CE). Preheating reduces the cooling rate, giving hydrogen time to escape and preventing the formation of brittle martensite and cold cracks in the heat-affected zone. Steels with a high CE require more preheating. Enter the steel's carbon equivalent.
Welding Travel Speed
Compute the welding travel speed (arc advance) by dividing the bead length by the time taken, in mm/min. It is a fundamental parameter that, together with voltage and current, defines the heat input: welding too fast produces narrow beads with little penetration; too slow overheats and deposits excess material. Enter the bead length and the welding time.
The results provided by this tool are for general informational and educational purposes only and do not constitute professional, financial, medical, legal, tax or accounting advice. Always confirm important decisions with a qualified professional and official sources.