Welding Heat Input (kJ/mm), Amperage Rule & Shielding Gas Calculator

Compute arc energy input (kJ/mm) and steel thickness amperage guidelines.

Net Welding Heat Input (kJ/mm)
0.54 kJ/mm
Heat Input per Inch (kJ/in) 13.83 kJ/in
Gross Electrical Arc Power 3.63 kW
Rule-of-Thumb Steel Thickness (1A/mil) 4.19 mm
Inputs
V
Arc welding voltage (V).
A
Welding current in Amperes (A).
mm/min
Torch travel speed in millimeters per minute (mm/min).
η
Process thermal efficiency η (0.80 MIG/Stick, 0.60 TIG, 1.0 SAW).
Results & Graph
Net Welding Heat Input (kJ/mm)
0.54 kJ/mm
Heat Input per Inch (kJ/in)
13.83 kJ/in
Gross Electrical Arc Power
3.63 kW
Rule-of-Thumb Steel Thickness (1A/mil)
4.19 mm

Net Welding Heat Input (kJ/mm)

Graph 1 • Welding Volts Sensitivity Recalculates the domain equation across 50% to 150% of the primary input while holding other parameters constant.
0 kJ/mm 0.5 kJ/mm 1.1 kJ/mm 50%: 0.27 kJ/mm 0.3 50% 75%: 0.41 kJ/mm 0.4 75% 100%: 0.54 kJ/mm 0.5 100% 125%: 0.68 kJ/mm 0.7 125% 150%: 0.82 kJ/mm 0.8 150%
Graph 2 • Primary & Supporting Metric Comparison Compares the primary output alongside supporting domain benchmarks.
Net Welding Heat Input (kJ/mm) 0.54 kJ/mm Heat Input per Inch (kJ/in) 13.83 kJ/in Gross Electrical Arc Power 3.63 kW Rule-of-Thumb Steel Thickness (1A/mil) 4.19 mm
Graph 3 • Exact Output Table & Units Displays each calculated output in its exact domain unit.
Net Welding Heat Input (kJ/mm)0.54 kJ/mmHeat Input per Inch (kJ/in)13.83 kJ/inGross Electrical Arc Power3.63 kWRule-of-Thumb Steel Thickness (1A/mil)4.19 mm
Summary: At 22 V and 165 A (3.63 kW arc power) traveling 320 mm/min (η=0.8), net heat input is 0.545 kJ/mm (13.83 kJ/in).
Summary: At 22 V and 165 A (3.63 kW arc power) traveling 320 mm/min (η=0.8), net heat input is 0.545 kJ/mm (13.83 kJ/in).
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Formula & Mathematical Methodology: Welding Heat Input & Amps Formula

HeatInputkJ/mm = ArcEfficiency_η × Volts × Amps × 601000 × TravelSpeedmm/min
HeatInput_kJ/mm = (ArcEfficiency_η × Volts × Amps × 60) / (1000 × TravelSpeed_mm/min)
  • weldingVolts: Welding Volts (V)
  • weldingAmps: Welding Amps (A)
  • travelSpeedMmPerMin: Travel Speed Mm Per Min (mm/min)
  • processThermalEfficiency: Process Thermal Efficiency (η)

Rounding: Physical package counts round up where appropriate; continuous measurements round to 2 decimal places.

Worked Example: Practical Benchmark: Welding Heat Input & Amps

Compute arc energy input (kJ/mm) and steel thickness amperage guidelines.

  1. Enter your project dimensions, machining speeds, or recipe weights.
  2. Compute the governing equation: HeatInput_kJ/mm = (ArcEfficiency_η × Volts × Amps × 60) / (1000 × TravelSpeed_mm/min).
  3. Review the primary result, supporting dimensions, and 3 SVG visualizations.
Result: Computes Welding Heat Input & Amps via HeatInput_kJ/mm = (ArcEfficiency_η × Volts × Amps × 60) / (1000 × TravelSpeed_mm/min).

Frequently Asked Questions

How does the Welding Heat Input (kJ/mm), Amperage Rule & Shielding Gas Calculator calculate results?

It evaluates HeatInput_kJ/mm = (ArcEfficiency_η × Volts × Amps × 60) / (1000 × TravelSpeed_mm/min) directly in your browser and plots three custom SVG visualizations.

Can I compare different material dimensions or batch sizes side by side?

Yes. Click "Compare (0/3)" in the results toolbar to pin up to 3 scenarios side by side.

Can I print a clean shop or kitchen reference sheet?

Yes. Click the Print button in the results toolbar for a distraction-free worksheet.

Science & Engineering · Mechanical & Shop Engineering

Welding Heat Input (kJ/mm), Amperage Rule & Shielding Gas Calculator: inputs, method, and how to read the result

Compute arc energy input (kJ/mm) and steel thickness amperage guidelines.

Choose inputs for the case you are checking

The defaults are illustrative. Replace them with values for your case and keep the units shown beside each field.

  • Welding Volts: Arc welding voltage (V).
  • Welding Amps: Welding current in Amperes (A).
  • Travel Speed Mm Per Min: Torch travel speed in millimeters per minute (mm/min).
  • Process Thermal Efficiency: Process thermal efficiency η (0.80 MIG/Stick, 0.60 TIG, 1.0 SAW).

What the calculation includes

With the default values shown, Net Welding Heat Input (kJ/mm) is 0.54 kJ/mm. The calculation follows Welding Heat Input & Amps Formula; the formula and variable definitions above show how the inputs combine.

One-input check: With the other defaults held constant, changing Welding Volts from 22 V to 24 V changes Net Welding Heat Input (kJ/mm) from 0.54 kJ/mm to 0.59 kJ/mm. This is a comparison inside the calculator's stated model, not a prediction.

Where to use caution

  • Uses standard North American & metric trade dimensions, Machinery’s Handbook formulas, and culinary weight ratios.
  • Verify local municipal building codes, tool manufacturer limits, and food-safety time/temperature tables before execution.

Scope: Trade, Shop & Culinary Science Reference Standard Check the assumptions and limitations against your situation before relying on the estimate.

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