Weld Deposition Rate Calculator
Find the deposition rate of a MIG or wire process in pounds and kilograms per hour from wire feed speed, wire size and efficiency.
How it works
Deposition rate (lb/hr) = WFS × wire area × 0.284 lb/in³ × 60 × efficiency · area = π × d² ÷ 4 · kg/hr = lb/hr × 0.4536
Deposition rate is how fast weld metal actually lands in the joint, and it drives both weld cost and job time. It equals the volume of wire fed per minute (feed speed times cross-section), converted to weight and scaled to an hour, then reduced by deposition efficiency for spatter and losses. Fatter wire and faster feeds raise the rate, which is why heavy fabrication favours large-diameter wire and high-deposition processes — but only up to the point where heat input and quality still hold.
Worked example
At 300 in/min with 0.035-inch wire (area 0.000962 in²) and 95% efficiency: 300 × 0.000962 × 0.284 × 60 × 0.95 = 4.67 lb/hr, about 2.12 kg/hr. Before efficiency the machine is feeding roughly 4.92 lb/hr of wire.
Frequently asked questions
What is a typical MIG deposition rate?
Short-circuit MIG on thin steel runs about 2–5 lb/hr, while spray transfer with larger wire can exceed 8–12 lb/hr. Submerged-arc and multi-wire setups go far higher.
How does deposition rate affect cost?
Faster deposition means fewer labour hours per pound of weld, and labour usually dwarfs consumable cost. Raising deposition rate is the single biggest lever on total welding cost — as long as quality is maintained.
Why multiply by efficiency?
Not all the wire you feed ends up in the joint — spatter and slag are lost. Efficiency (about 95% for solid MIG, 80% for flux-core) converts wire fed into weld metal actually deposited.
Related calculators
This calculator is for educational purposes. Double-check important results before acting on them.