🔥 Welding Calculator
Calculate welding parameters and heat input
How to Use This Calculator
Select Welding Type
Choose welding process (MIG, TIG, Stick, or Flux-Core). Different processes have different parameter calculations.
Select Material Type
Choose material type (steel, stainless steel, aluminum, cast iron). Material affects preheat and interpass temperatures.
Enter Parameters
If calculating from thickness, enter material thickness and wire diameter (for MIG/Flux-Core). If calculating heat input, enter amperage, voltage, and travel speed.
Calculate and Review
Click "Calculate Welding Parameters" to see recommended amperage, voltage, wire feed speed (if applicable), heat input, and temperature requirements.
Formula
Amperage ≈ 125 × Material Thickness (MIG/Steel)
Voltage ≈ 14 + (0.5 × Amps / 10) (MIG approximate)
Heat Input = (Voltage × Amperage × 60) / Travel Speed
Wire Feed Speed ≈ Amps / Wire Factor
Example 1: From Thickness (MIG, Steel, t = 0.125", Wire = 0.035")
Step 1: Amperage ≈ 125 × 0.125 = 15.6 Amps (round to 16 Amps for thin material, use higher for thicker)
Step 2: For 0.125" steel, typical: 125-150 Amps
Step 3: Voltage ≈ 14 + (0.5 × 125 / 10) = 14 + 6.25 = 20.25 Volts
Step 4: Wire Feed Speed ≈ 125 / 1.5 = 83.3 in/min
Example 2: Heat Input (Amps = 125, Volts = 20, Speed = 10 in/min)
Step 1: Heat Input = (Voltage × Amps × 60) / Speed = (20 × 125 × 60) / 10 = 15,000 J/in
Step 2: Heat Input (kJ/m) = 15,000 × 0.0394 = 591 kJ/m
About Welding Calculator
The Welding Calculator is an essential tool for welders, welding engineers, and fabricators who need to calculate welding parameters and heat input for welding operations. This calculator implements standard welding formulas for MIG, TIG, Stick, and Flux-Core welding, helping you optimize welding settings and ensure proper weld quality.
When to Use This Calculator
- Welding Setup: Calculate welding parameters for machine setup
- Heat Input Control: Calculate and control heat input for weld quality
- Parameter Optimization: Optimize amperage, voltage, and wire feed speed
- Weld Procedure Development: Develop welding procedures for specific materials
- Educational Use: Learn and understand welding calculations
Why Use Our Calculator?
- ✅ Multiple Processes: Supports MIG, TIG, Stick, and Flux-Core welding
- ✅ Material Support: Includes steel, stainless steel, aluminum, and cast iron
- ✅ Accurate Formulas: Uses standard welding equations
- ✅ Complete Parameters: Shows amperage, voltage, wire feed speed, and heat input
- ✅ Time Savings: Instant calculations eliminate manual math
Understanding Welding Parameters
Basic Principle: Welding parameters (amperage, voltage, wire feed speed, travel speed) determine weld quality, penetration, and heat input. Amperage controls penetration and deposition rate, voltage controls arc length and bead width, wire feed speed controls amperage (for MIG), and travel speed controls heat input and bead size.
Heat Input: Heat input is calculated as Heat Input = (Voltage × Amperage × 60) / Travel Speed (Joules per inch). Heat input affects weld microstructure, hardness, and mechanical properties. Higher heat input increases penetration but may reduce strength. Typical values: 10-40 kJ/in for most applications.
Parameter Selection: Parameter selection depends on material thickness, material type, welding process, and joint type. Thicker materials require higher amperage. Different materials require different voltage and amperage ranges. Use manufacturer recommendations and test welds for optimal settings.
Tips for Best Results
- Start with Recommendations: Use calculator recommendations as starting point
- Test Weld: Test weld on scrap material and adjust parameters as needed
- Consider Material: Adjust parameters based on material grade and condition
- Monitor Heat Input: Control heat input for desired weld properties
- Follow Procedures: Use established welding procedures for critical applications
Frequently Asked Questions
How do I calculate welding amperage?
Welding amperage depends on material thickness, welding process, and material type. For MIG steel: Amps ≈ 125 × Thickness (inches). For example, 0.125" steel: Amps ≈ 125 × 0.125 = 15.6 Amps (use 125-150 Amps for typical 0.125" steel). Actual amperage varies by process and material. The calculator provides recommendations based on material thickness.
How do I calculate heat input?
Heat Input = (Voltage × Amperage × 60) / Travel Speed (Joules per inch). For example, Volts = 20, Amps = 125, Speed = 10 in/min: Heat Input = (20 × 125 × 60) / 10 = 15,000 J/in (591 kJ/m). Heat input affects weld microstructure and mechanical properties. Higher heat input increases penetration but may reduce strength.
What are typical welding parameters?
Typical MIG parameters for 0.125" steel: Amps = 125-150, Volts = 18-22, Wire Feed = 200-300 in/min. Typical TIG parameters: Amps = 80-120, Volts = 10-12. Typical Stick parameters: Amps = 100-140, Volts = 20-25. Parameters vary by material thickness, material type, and welding process. Use calculator recommendations as starting point.
Does wire diameter affect settings?
Yes, wire diameter affects amperage and wire feed speed. Larger wire requires higher amperage for same deposition rate. Smaller wire (0.023") requires lower amperage but higher wire feed speed. Larger wire (0.045") requires higher amperage but lower wire feed speed. The calculator accounts for wire diameter in calculations.
How do I control heat input?
Control heat input by adjusting voltage, amperage, or travel speed. Higher voltage or amperage increases heat input, higher travel speed decreases heat input. For same heat input, you can increase voltage/amperage if you increase travel speed proportionally. Use heat input calculator to verify and control heat input for desired weld properties.