BIZOMAT MAKEOS · Fabrication
Fillet Weld Quantity
How much deposited metal and consumable does this fillet require?
Estimate equal-leg fillet volume and mass with a supplied profile allowance, density and deposition efficiency.
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How this tool works
Inputs, units and where to find them
| Input | Unit | Typical source |
|---|---|---|
| Equal fillet leg size | mm | Equal leg on a 90° joint, not throat size. |
| Total deposited weld length | mm | Total actual weld length; count both sides separately where required. |
| Deposited metal density | kg/m³ | Deposited metal density from a relevant material source. |
| Profile volume factor | × | Justified multiplier over ideal triangular volume; 1 means ideal triangle. |
| Deposition efficiency | % | Deposited mass/consumed filler mass on the same accounting basis, from demonstrated process data. |
What each input means
Open an input to see what it is, its units, the worked example and the common mistakes, with a small diagram.
What this means: Equal fillet leg size
- What it is
- The length of each leg of an equal-leg fillet weld, measured from the joint root to the toe along each plate, for a 90° joint.
- Units and format
- Enter a number in mm: millimetres. The form accepts 0.001 mm to 1000 mm. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 6 mm as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Weld volume and mass rise with the square of leg size.
- Get it right
- Do not enter the throat size; on an equal-leg fillet the throat is the leg divided by √2.
What this means: Total deposited weld length
- What it is
- The total length of fillet weld to be deposited on the job, adding every run.
- Units and format
- Enter a number in mm: millimetres. The form accepts 0 mm to 100000000 mm. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 1000 mm as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Volume and mass are directly proportional to weld length.
- Get it right
- A joint welded on both sides counts twice; add the length of each side.
What this means: Deposited metal density
- What it is
- The mass per unit volume of the deposited weld metal, from the filler or base material data.
- Units and format
- Enter a number in kg/m³: kilograms per cubic metre. The form accepts 0.001 kg/m³ to 100000 kg/m³. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 7850 kg/m³ as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Deposited and consumed mass are directly proportional to density.
- Get it right
- Take it from a material data source for the actual alloy; stainless and aluminium differ widely from carbon steel.
What this means: Profile volume factor
- What it is
- A multiplier on the ideal triangular fillet volume to allow for convexity, excess weld metal and other profile effects. 1 means a perfect flat triangle.
- Units and format
- Enter a number in ×: a multiplier (type 1.5 for 1.5 times). The form accepts 1 × to 10 ×. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 1.1 × as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Weld volume and mass are directly proportional to this factor.
- Get it right
- Base it on measured welds or your process records rather than a guess.
What this means: Deposition efficiency
- What it is
- The percentage of consumed filler that ends up as deposited weld metal, after spatter, stub ends and slag losses, from demonstrated process data.
- Units and format
- Enter a number in %: percent: the number is read as a percentage, so type 8 for 8 %. The form accepts 0.001% to 100%. Required: the tool does not calculate until every input is valid.
- Example
- The form opens with 95% as a worked example. It is an illustration, not a recommended value: replace it with your own figure.
- Effect on the result
- Consumed filler is inversely proportional to efficiency.
- Get it right
- Use deposited mass divided by consumed filler mass on the same basis; this is not the arc energy efficiency.
Method and formulas
- Ideal area = leg²/2; geometric throat = leg/√2 for a flat-faced equal-leg 90° fillet.
- Volume = area × length × profile factor. Mass = volume/10⁹ × density. Consumed filler = deposited mass/(efficiency/100).
- Example: 6 mm legs over 1000 mm, profile factor 1.1, density 7850 kg/m³ and 95% efficiency gives 0.15543 kg deposited and 0.163611 kg consumed filler.
Limitations
- No strength, required weld size, penetration, distortion or procedure qualification is evaluated. Geometric throat is not a design acceptance value.
- Unequal legs, grooves, concavity and gaps need another section model.
- Flux, stubs, packaging and purchasing waste may require separate allowances on a consistent efficiency basis.
- Default values are worked examples, not recommended settings or material properties.
Typical uses
- weld metal quantity
- fillet volume
- consumable estimate
Who it is for
- Welding estimators
- Fabrication planners
What you get
- Ideal area and geometric throat
- Adjusted deposited volume and mass
- Consumed filler mass
Interpreting the result
- Use approved geometry and measured profile/deposition data.
- Estimate arc time, labour, access and inspection separately.
References
- Machinery’s Handbook, 29th edition (Industrial Press, 2012), printed pp. 1437–1452. Topic reference; implementation and examples are original, and no source tables are reproduced.
- Method: triangular geometry, volume and mass balance; no weld design standard is substituted.
Learn the Concepts Behind This Tool
These BIZOMAT Library readings explain the method this tool uses, with worked examples.
Method explained here · BIZOMAT original book
Weld metal in fillet welds
What it covers: Calculate the throat, cross-section and mass of fillet welds, see how fast weld metal grows with leg size and gaps, and estimate the weld metal in a conveyor frame.
Method explained here · BIZOMAT original book
The self-regulating arc and wire feed
In Welding Automation by the Numbers
What it covers: See how wire fed at a constant speed into a constant-voltage arc keeps its own length steady, calculate deposition from wire feed speed, and see why stick-out and torch angle matter to a machine.
Useful alongside · BIZOMAT original book
Fillet welds: throat, length and capacity
In Designing Welded Joints by the Numbers
What it covers: Size fillet welds from the throat, calculate the load a millimetre of weld can carry at each size, find the length a joint needs, and see why doubling the leg nearly quadruples the weld metal.
BIZOMAT tools are screening and decision-support utilities. Verify important financial, engineering, safety, legal or operational decisions using appropriate professional standards and your organisation’s approved data.