Coil Usage calculation in SAW

Theoretically, length of weld x area of fillet = length of wire x area of wire. Thus,

1 x (3mm)^2 / 2 = length of wire x (pi) (1.6)^2.

4.5 = length of wire x 8.042.

Length of wire = 4.5/8.042 = 0.56 m.

In case the weld contour varies, you might add 20%, allowing 0.672 m of wire per meter of weld. If the actual wire usage is less than 0.56, check that the weld is full size and not concave; if the usage is more than 0.672, check that the weld is not excessively convex (i.e. not built up too high); also that not too much spattering occurs. In other words, maintain the ideal 45-degree shape.

Good luck with your project.

that was a great explanation thank you very much and can you tell me how to calculate the weight of the wire from from its length...

I work in antique British units, in which steel alloys weigh 490 lb/ft^3. In metric units, this is very close to 2400 kg/m^3, or 0.0000024 kg/mm^3. From before, your wire is 8.042 mm^2 in area. Thus 1m of wire = 8042 mm^3, and weighs 8042 x 0.0000024 = 0.0193 kg. If you can get manufacturer's data, their value should be very close to this 0.0193 kg/m, if those are the units they use.

Hi, thanks for your Prompt reply, can you please tell how you calculated that the steel alloy weights approx. 2400kg/m^3 or close to 2400kg/m^3 in metric unit ...

thanks & Regards

I apologize; the earlier calculation was in error.

Conversion factors: 1 kg = 2.2 lb; 1 m = 3.2080 ft.

Thus, 1 m^3 = 35.31 ft^3;

35.31 x 490 lb = 17,302 lb;

17,302 lb/2.2 = 7865 kg.

(My error was 3.2808^2 versus 3.2808^3; I miskeyed the exponent.)

7865 kg/m^3 = 0.000007865 kg mm^3.

As before, 8042 mm^3 per meter of wire times 0.000007865 = 0.0633 kg/m.

Thank you for calling attention to this, so that I could revisit it. I hope this helps.