Electrode Efficiency Calculator
Calculate deposition efficiency and consumable requirements for welding.
Typical Deposition Efficiencies
| Process/Type | Efficiency | Notes |
|---|---|---|
| SMAW E6010 | 55-60% | High stub/slag loss |
| SMAW E7018 | 60-65% | Standard stick |
| SMAW E7024 | 65-70% | Iron powder coating |
| GMAW Solid | 93-98% | Minimal loss |
| GMAW Metal Core | 88-93% | Some flux loss |
| FCAW-G | 82-88% | Flux/slag loss |
| SAW | 95-99% | Highest efficiency |
Understanding Electrode Efficiency
What is Deposition Efficiency?
Deposition efficiency is the ratio of weld metal deposited to the weight of electrode or wire consumed. Higher efficiency means less waste and lower consumable costs.
Sources of Loss
- Stub Loss (SMAW): Unusable electrode end, typically 50-75mm
- Slag/Flux: Coating that forms protective layer, not deposited
- Spatter: Metal droplets that don't become part of weld
- Fume: Vaporized metal lost to atmosphere
Improving Efficiency
- Process Selection: GMAW/SAW higher than SMAW
- Proper Parameters: Correct voltage/WFS reduces spatter
- Technique: Proper arc length and travel speed
- Stub Control: Use shorter stubs where safe