Flux Consumption Rate Calculator

Calculate flux consumption rate for submerged arc welding (SAW) and flux-cored arc welding (FCAW) based on welding parameters

Input Parameters

Results

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Flux Consumption Rate
lb/hr
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Total Flux Required
lb
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Flux per Foot of Weld
lb/ft
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Estimated Weld Time
hr
Note: SAW flux-to-wire ratios vary by joint type: narrow groove ~1.0, fillet ~1.3, wide groove ~1.7. Consider 50-70% flux recovery for unfused granular flux.

Reference

Flux Consumption = Wire Deposition Rate x Flux-to-Wire Ratio SAW flux-to-wire ratios: 1.0-1.7 typical - V-groove: 1.0-1.2 - Fillet weld: 1.2-1.5 - Deep groove: 1.3-1.7 FCAW: internal flux ~15-25% of wire weight Recoverable unfused SAW flux: 50-70%