Weld Penetration Calculator

Estimate weld penetration depth based on welding parameters and process characteristics.

DCEP provides deeper penetration for most processes

Penetration Characteristics by Process

Process Penetration Profile
GMAW SprayDeepFinger-like
GMAW ShortShallowWide, shallow
GTAWShallow-MedEven, controlled
SMAWMediumModerate depth
SAWVery DeepNarrow, deep

Understanding Weld Penetration

Factors Affecting Penetration

  • Welding Current: Primary factor - higher current = deeper penetration (proportional)
  • Travel Speed: Slower speed = more heat = deeper penetration
  • Arc Voltage: Affects arc length and width, less effect on depth
  • Polarity: DCEP (electrode positive) provides 2/3 of heat at workpiece
  • Electrode Size: Smaller diameter = higher current density = deeper penetration

Penetration by Process

  • GMAW Spray: Deep finger penetration due to high current density and arc force
  • GMAW Short Circuit: Shallow penetration, good for thin material and poor fitup
  • GTAW: Shallow to medium, very controllable
  • SMAW: Medium penetration, varies with electrode type (E6010 deep, E7018 moderate)
  • SAW: Very deep penetration due to submerged arc concentration

Penetration Rules of Thumb

  • GMAW: ~0.015 mm penetration per ampere (spray transfer)
  • SAW: ~0.025-0.030 mm penetration per ampere
  • GTAW: ~0.010 mm penetration per ampere
  • Doubling current increases penetration ~60-70%