Computations using simplified mathematical models were performed to predict weld geometries and penetration depth for grooved butt joints in CO2 welding. Weld metal geometry can be predicted within ± 10% accuracy using a fundamental equation derived from Wells’ concept. From the computations, it was shown that the widest tolerance is obtained with root gap 1·3–1·8 mm at which the most flexible combination of welding parameters can be selected. The flank angle at the ‘toe’ can be calculated best using the circular arc model for I-butt joints and the normal distribution model for V-butt joints.
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