🔥

Welding Parameter Wizard

⚙️ Mechanical · Approximate current, voltage, and heat input estimate for MIG/MAG and stick welding

🧮 Calculate∑ Formula✅ Verification📚 Sources

Welding Process

Material Thickness (mm)

Travel Speed (mm/min)

Estimated current I210–240 A

Estimated voltage V25 V

Heat input (η≈0.8)0.9 kJ/mm

Shielding gas flow (steel)7–12 L/dk

Transfer modeSpray transfer

💡 These values are semi-empirical rough estimates (Lesnewich voltage relation and general current/gas-flow rules) — they DO NOT REPLACE AN ACTUAL WELDING PROCEDURE SPECIFICATION (WPS). Always verify with a qualified WPS in production. Wire feed speed varies by the wire manufacturer's melting-rate curves and is therefore not calculated here.

🔒

A free EngineersLab account is required to use this tool.

V = 0.04\,I + 16

Commercial welding parameter assistants such as Fronius’s WeldConnect / Weld Wizard produce a current/voltage/wire-speed recommendation from material + thickness + process inputs; this tool is a simplified, semi-empirical closed-form version of the same idea.

MIG/MAG (GMAW) mode: Current scales linearly with thickness (I ≈ t × 35–40); voltage is estimated with the classic current-dependent Lesnewich relation (V = 0.04·I + 16). Heat input is calculated from voltage × current × travel speed and corrected with a typical thermal efficiency factor (η ≈ 0.8). Above roughly 220 A (1.2 mm wire, mixed gas), the transfer mode shifts from short-circuit/globular to spray transfer.

Stick (SMAW) mode: Current is approximately 1000 times the electrode diameter in inches — a simple rule of thumb widely used in the field.

Important limitation: this tool DOES NOT REPLACE AN ACTUAL WELDING PROCEDURE SPECIFICATION (WPS). Production use must always be verified with a qualified WPS. Wire feed speed varies significantly with the wire manufacturer’s melting-rate curves and is therefore not calculated here.

⚠️ Disclaimer: This tool IS NOT an actual Welding Procedure Specification (WPS) and does not replace one. Results are semi-empirical rough estimates for preliminary design/educational purposes only. Before any production use, results must be verified with a proper WPS prepared by a qualified welding engineer in accordance with the relevant standard (e.g., ISO 15614, ASME IX). Incorrect welding parameters can lead to serious safety risks; EngineersLab and its founder accept no liability for any consequences arising from the use of this information.

📖 Sourced Formula · Single Verification

This tool's formula is based on a reliable source (see the Sources tab below) and has been checked against a hand-computed numerical example. A second, independent literature cross-check has not yet been added. As with any engineering calculation, we recommend independently confirming results before relying on them for critical decisions.

[29] WeldFabWorld. MIG} Welding Settings Calculator — reference formulas. (Lesnewich gerilim bağıntısı ve akım/tel hızı kuralları) ↗
[30] Fronius International GmbH. WeldConnect — Digital Welding Parameter Assistant. 2024. ↗

Welding Parameter Wizard — EngineersLab calc card

Formula: V = 0.04·I + 16

Sources: [29] MIG} Welding Settings Calculator — reference formulas; [30] WeldConnect — Digital Welding Parameter Assistant

Tool version: 1.0.0 · Date:

Source URL: https://engineerslab.com.tr/en/araclar/kaynak-sihirbazi

Results are for educational and preliminary-sizing purposes; final engineering design decisions must reference the relevant standards and a licensed engineer's approval.