Deposition rate estimates how much weld metal a process can place over time. It rises with wire-feed speed, but it is not the same as wire melt-off rate: some metal is lost as spatter or otherwise does not end up in the weld. The table below is limited to one published Lincoln Electric product procedure, Metalshield MC-80 XLS metal-cored GMAW-C wire, using DC positive polarity and 90% argon/10% carbon dioxide.

Metal-cored wire deposition rates

Select the exact wire diameter first, then use the matching wire-feed-speed row. The voltage and approximate current shown are part of the manufacturer’s procedure context. The rows are not generic settings for solid wire, flux-cored wire, other metal-cored products, or another shielding gas.

Deposition rate versus melt-off rate

Melt-off rate describes the mass of electrode wire consumed per hour at a given operating point. Deposition rate describes the mass of weld metal deposited per hour. The ratio of those values is the deposition efficiency shown in the source data. For example, the first 0.045-inch row reports a 5.0 lb/h melt-off rate and a 4.6 lb/h deposition rate, or 89% typical efficiency. At higher listed wire-feed speeds the manufacturer reports different rates and efficiencies, so the efficiency should be read from the matching row rather than treated as a constant.

Wire-feed speed is a control setting in inches per minute, not travel speed along the joint. Travel speed, bead size, joint shape, position, duty cycle, operator technique and the number of passes affect production output. The table’s deposition rate is a consumable/process reference under the stated conditions; it does not promise that a finished joint will have a particular strength or that an entire shift will deposit that amount.

Using the table to plan a procedure

A welding engineer can use a row to compare process capacity while preparing a procedure or estimating wire consumption. First confirm that Metalshield MC-80 XLS is the selected wire and that the machine, gun, liner, contact tip and feeder can run the listed diameter and feed speed. Then check the current data sheet for contact-tip-to-work distance, voltage range, approximate current and shielding gas. The source provides different contact-tip-to-work distance ranges for the 0.045-inch entries at lower and higher wire-feed speeds.

If a job requires a deposition rate of 8 lb/h, do not assume any wire or machine can achieve that target because a row in a table reaches it. For this product and gas, the 0.052-inch section lists operating points around that range, but selecting one also sets approximate current, voltage and distance conditions. Confirm the power source output and duty cycle, and validate the complete welding procedure for the material, thickness, joint, position and service requirements. A qualified procedure specification and applicable code take precedence over this reference.

Important limits

This table is a selected transcription of manufacturer typical operating data, not a comparison of every GMAW transfer mode. Metal-cored GMAW-C behavior differs from solid-wire short-circuit or spray procedures. The rows do not specify every weld position, joint preparation, preheat, interpass temperature, wire classification test condition or code requirement. Consult the complete current Lincoln Electric product data sheet and your qualified welding documentation before applying the settings.

Do not confuse a high deposition rate with high productivity in every joint. More deposited metal can mean more passes, distortion, cleanup or rework if fit-up and technique are poor. The listed efficiency values are typical manufacturer data, not a guaranteed measurement for a particular operator or setup. Use the stated polarity, shielding gas and contact-tip distance as part of the selection context.

Related engineering references

Browse more welding and manufacturing topics in the Mechanitec Engineering category.

Sources

• Lincoln Electric Metalshield MC-80 XLS product data sheet, typical operating procedures.