Welding Cost Calculator
Filler metal consumption, arc time, and labor cost for fillet and butt welds — MIG, TIG, stick, flux-core
Welding cost is dominated by labor, not consumables — typically 70–85% of the total. The chain of arithmetic: weld cross-section area → weld metal weight → filler consumption (divided by deposition efficiency) → arc time (divided by deposition rate) → total labor time (divided by the arc-on factor, since no welder burns wire 100% of the shift).
This calculator covers the two most common joints. A fillet weld’s cross-section is z²/2 (plus ~10% reinforcement); a 60° V-butt is t²·tan30° plus the root-gap area. Steel density 7,850 kg/m³ is assumed — the standard for structural work.
Process defaults are editable: MIG solid wire deposits ~3 kg/h at 95% efficiency, flux-core ~4 kg/h at 85%, stick ~1.5 kg/h at 65% (stub loss and spatter), TIG ~1 kg/h at 98%. The arc-on factor is where most estimates go wrong: 30% is a realistic shop average — fit-up, repositioning, and cleaning consume the rest.
Frequently Asked Questions
How is welding cost calculated?
Weld metal weight = cross-section area × length × density. Filler = weight / deposition efficiency. Arc time = weight / deposition rate. Labor time = arc time / arc-on factor. Cost = filler × price + labor time × rate. This calculator chains all of it from four inputs.
How much filler wire does a fillet weld consume?
A 5 mm fillet in steel holds about 0.108 kg of weld metal per meter (with 10% reinforcement). At 95% MIG efficiency that is ~0.113 kg of wire per meter. Doubling the leg size quadruples consumption — legs enter squared.
What is a realistic arc-on (operating) factor?
Manual welding shops average 20–40%; 30% is a fair default. Robotic cells reach 70–90%. Using 100% in an estimate roughly triples the apparent productivity and destroys the quote.
Why is stick welding cheaper on filler but pricier overall?
Stick electrodes are cheap per kg, but efficiency is ~65% (stub ends, slag, spatter) and deposition is slow — so labor hours grow. For long welds MIG/FCAW almost always wins on total cost.