WPS Heat Input Range
Calculates a minimum/maximum nominal (and, if an efficiency factor is supplied, effective) heat-input range from entered voltage, current, and travel-speed ranges — Q (kJ/mm) = (U x I) / (v x 1000), the same formula already implemented as FR-001. This is an arithmetic range calculation only: it does not approve a WPS/WPQR, does not check a standard qualification range, and does not predict HAZ hardness, cracking, toughness, corrosion, or mechanical properties.
Engineering calculator — results require technical review before production use.
Source & assumptions
IWE Module 2 – Materials and Their Behavior during Welding, Chapter 5, Section 2 (Heat Input)
Assumptions
- Q (kJ/mm) = (U × I) / (v × 1000) — the same source-stated formula already implemented and registered as FR-001's Arc Energy / Nominal Heat Input, reused here (via calculateHeatInput) rather than re-derived, for both boundary points of the range.
- The entered voltage, current, and travel-speed ranges represent the intended WPS parameter bounds (e.g. a min/max range from a procedure specification) — not a measured or recorded production range.
- Minimum heat input occurs at minimum voltage, minimum current, and MAXIMUM travel speed — because Q increases with U and I, and decreases with v.
- Maximum heat input occurs at maximum voltage, maximum current, and MINIMUM travel speed — for the same reason.
- Travel speed is normalized to mm/s before calculation, using the same conversion already implemented and used by FR-001 (and by FR-006's travel-speed selector) — no new conversion logic was added.
- An efficiency factor, if entered, is applied uniformly to both the minimum and maximum nominal heat input (0 < η ≤ 1), the same convention as FR-001.
- No sanity-check ('unusually high') warnings are implemented for voltage, current, or travel speed — FR-001 itself defines no such thresholds for these fields, and none were provided as a basis for this calculator, so none are invented here.
- Result requires engineering review — this calculator does not decide whether a heat-input range is acceptable for a given application, standard, or procedure.
Limitations
- Calculates an arithmetic heat-input range only.
- Does not approve a WPS or WPQR.
- Not an ISO 15614 or other standard qualification-range determination.
- Not a welding procedure acceptance decision.
- Not a HAZ hardness prediction.
- Not a cracking, toughness, corrosion, or mechanical-property assessment.
- Does not account for waveform, pulsed welding, arc power variation, actual travel-speed variation, stop/start effects, weaving, bead shape, joint geometry, interpass temperature, or heat losses beyond the entered efficiency factor.
- Does not replace procedure qualification, welding coordination review, material review, production testing, or engineering judgement.
- Results require technical review before production use.