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WAAM Wire Deposition Calculator

DED

Deposition rate, bead geometry, and heat input for MIG-WAAM, TIG-WAAM, and CMT. Empirical bead geometry model based on Rodrigues et al. (2019).

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Formulae

Physics and empirical relations used in this calculator.

ṁ = A_wire × WFS × ρ
ṁ
Mass deposition rate[kg/h]
A_wire
Wire cross-section (π × (d/2)²)[mm²]
WFS
Wire feed speed[mm/s]
ρ
Material density[g/mm³]

Volume deposition rate in mm³/s, converted to cm³/h (÷1000) and kg/h (× density × 3600 ÷ 1000).

H = (η × V × I) / v
H
Linear heat input[J/mm]
η
Thermal efficiency (MIG 0.80, TIG 0.60, CMT 0.85)[—]
V
Arc voltage[V]
I
Welding current[A]
v
Travel speed[mm/s]

Heat input drives bead geometry. Cap at 10 J/mm for bead size extrapolation.

w = 2.5 + 0.18 × H (capped 4–18 mm)
w
Bead width[mm]
H_cap
H capped at 10 J/mm[J/mm]

Empirical fit from Rodrigues et al. (2019). Bead height = w / aspect ratio (MIG 3.2, TIG 2.8, CMT 3.5).

Sources