Practical Considerations
Weld-metal Recovery
This should not be confused with an electrode efficiency. Weld-metal recovery measures the amount of weld metal that will be deposited on the workpiece.
For example, if you purchase a 5kg packet of MMA E6012 electrodes, which will produce a weld-metal recovery of around 60%, you will end up with 2kg as slag and stubs. Using a GMAW solid wire at 93%, you will lose only 0.35kg to slag and stubs.
Figures stated are indicators only as the operator and welding envelope will influence actual figures.
Various Process Efficiencies
Welding processes vary in both the deposition rates and deposition efficiencies. The following table gives an indication of the various processes. The GTAW and oxy-acetylene processes assume that the stubs are joined together to have no waste.
Approximate Process-deposited Weld-metal
Recovery (not Electrode Efficiency)
| Welding Process | Average Efficiency |
|---|---|
| GTAW | 100% |
| Oxy-acetylene Welding | 99.9% |
| GMAW - Pulse Arc | 98% |
| GMAW - Spray Arc | 95% |
| GMAW - Short (Dip) Arc | 93% |
| FCAW - E70C-6M Types | 92% |
| FCAW - E70T-S Types | 88% |
| FCAW - E71T-I Types | 85% |
| FCAW - Tubular Hard-facing Wires | 80-85% |
| FCAW - E70T-4 Types | 82% |
| MMA - Hard-facing Types | 62-72% |
| MMA - E7014 Types | 63% |
| MMA - E7016 Types | 61% |
| MMA - E7024 | 60% |
| MMA - E6012 Types | 60% |
| MMA - E7018 Types | 58% |
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