Welding Cost Calculator
Add up the real cost of a weld: filler metal, labor, shielding gas and electricity. Set a deposition efficiency so the filler line reflects electrode bought, not just metal deposited.
How to estimate welding cost
- Enter deposited filler weight, its cost per pound, and a deposition efficiency.
- Enter labor hours and rate, then optional gas and power figures.
- Read the filler, labor, gas, power and total cost breakdown.
Examples
Single weld breakdown
2 lb filler at $3, 0.9 eff, 1.5 hr at $40, 50 cf gas at $0.30
Filler $6.67, labor $60, gas $15, total $81.67
Frequently asked questions
What goes into welding cost?
The four big buckets are filler metal, labor, shielding gas and electricity. Labor usually dominates, so faster deposition or less rework often saves more than a cheaper electrode.
Why divide filler weight by deposition efficiency?
You pay for the whole electrode, but only the deposited part ends up in the weld. Spatter, slag and stub loss mean you buy more than you deposit, so weight purchased equals deposited weight divided by efficiency.
What deposition efficiency should I use?
Solid MIG wire is often near 0.95, flux-cored around 0.80 to 0.90, and stick about 0.60 to 0.70 including stub loss. The default 0.9 is a reasonable mid value; set it to match your process.
Are gas and power required?
No. Leave gas and power blank and they count as zero. Add them when you want a fuller picture; for stick welding there is no shielding gas line.
Does this include overhead and consumables?
No. It covers filler, labor, gas and power only. Add tips, nozzles, grinding discs, machine wear and shop overhead separately for a full quoted price.
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