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    Weld Cost Calc XL1.3.2mm

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    Vipin Jose
    This document summarizes the cost analysis for two welding processes used to weld a single-V groove joint: SMAW (stick welding) and FCAW (gas welding). The SMAW process would require 2.7 kg of filler metal, take 3.29 hours to complete, and have a total cost of $157.10 per meter welded. The FCAW process would require 1 kg of filler metal, take 0.69 hours to complete, and have a total cost of $41.94 per meter welded, providing a 73% savings over the SMAW process.

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    Weld Cost Calc XL1.3.2mm

    Uploaded by

    Vipin Jose
    259 views3 pages
    This document summarizes the cost analysis for two welding processes used to weld a single-V groove joint: SMAW (stick welding) and FCAW (gas welding). The SMAW process would require 2.7 kg of filler metal, take 3.29 hours to complete, and have a total cost of $157.10 per meter welded. The FCAW process would require 1 kg of filler metal, take 0.69 hours to complete, and have a total cost of $41.94 per meter welded, providing a 73% savings over the SMAW process.

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    This document summarizes the cost analysis for two welding processes used to weld a single-V groove joint: SMAW (stick welding) and FCAW (gas welding). The SMAW process would require 2.7 kg of filler metal, take 3.29 hours to complete, and have a total cost of $157.10 per meter welded. The FCAW process would require 1 kg of filler metal, take 0.69 hours to complete, and have a total cost of $41.94 per meter welded, providing a 73% savings over the SMAW process.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    259 views3 pages

    Weld Cost Calc XL1.3.2mm

    Uploaded by

    Vipin Jose
    This document summarizes the cost analysis for two welding processes used to weld a single-V groove joint: SMAW (stick welding) and FCAW (gas welding). The SMAW process would require 2.7 kg of filler metal, take 3.29 hours to complete, and have a total cost of $157.10 per meter welded. The FCAW process would require 1 kg of filler metal, take 0.69 hours to complete, and have a total cost of $41.94 per meter welded, providing a 73% savings over the SMAW process.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document compares the costs and productivity of shielded metal arc welding (SMAW) and flux-cored arc welding (FCAW) processes for a single-V groove weld.

    The welding processes being compared are shielded metal arc welding (SMAW) and flux-cored arc welding (FCAW).

    The factors considered in determining the welding cost include amount of filler metal and shielding gas used, labor time, electrode/filler material cost, gas cost, power cost, and deposition rate.

    DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD

    Mark Mruczek Welding Engineer Mruczek Welding Engineering Project: AWS Board Company: Subject: MMAW Example Welding process(es) Used: SMAW Base Material: Product Form: Filler Material Trade Name: CS Plate E71T-1 Lincoln Date: Page:
    Choose Units For This Sheet

    10/22/07 1 of 3
    English Units Metric Units

    Please choose units before you enter data into the fields below Process 1 Thickness (mm) 14 mm Height of H (mm) 1.000 mm Root Opening (mm) 2 mm Root Face (mm) 2 mm
    Filler material Process Gas Used
    Carbon Steel SMAW (14" Stick) N/A

    Process 2 Thickness (mm) Height of H (mm) Root Opening (mm) Root Face (mm) Filler material Process Gas Used

    14 1 2 2

    mm

    mm
    mm mm

    Carbon Steel FCAW (Gas) 75Ar-25C02

    130 A Amps Volts 21 V Wire Feed (m/min) 0 m/min Electrode Diam. (mm) 3.200 mm Joint Angle (deg) 70 deg Total Weld Length (m) 1.00 m Travel Speed (m/min) 0.127 m/min Gas Flow Rate (L/min) 0 L/min Welder Efficiency 30% Cost Electrode ($/kg) 4.96 $/kg Labor Rate 45.00 $/hr Cost of Gas $/bottle Gas Cylinder Size (m^3) 0 m^3 Power Cost 0.20 $/kwh
    Cost of Flux ($/kg)

    Scroll Down To See Results

    Amps 250 A Volts 27 V Wire Feed (m/min) 8.382 m/min Electrode Diam. (mm) 1.143 mm Joint Angle (deg) 70 deg Total Weld Length (ft) 1.00 m Travel Speed (m/min) 0.254 m/min Gas Flow Rate (L/min) 17 L/min 45% Welder Efficiency Cost Electrode ($/kg) 7.19 $/kg Labor Rate 45.00 $/hr Cost of Gas 40.00 $/bottle Gas Cylinder Size (m^3) 9.34 m^3 Power Cost 0.20 $/kwh Cost of Flux ($/kg)

    2 2

    $/kg

    $/kg

    Units = Last

    Units = Last

    WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD


    OUTPUT FOR Process 1 Amount of filler metal needed Number of passes per joint ~ Amount of shielding gas Number of Gas Bottles Required Actual welding time Deposition Rate Labor Cost Welding Electrode Cost Gas Cost Flux Cost Power Cost Initial Cost 0% Final Cost Total cost per meter of weld Filler cost per meter of weld Flux cost per meter of weld Gas cost per meter of weld Labor cost per meter of weld Shift Productivity 1.74 7 0.00 N/A 3.29 1.12 $147.95 $8.61 $0.54 $157.10 $157.10 157.10 8.61 147.95 2.70 kg m^3 hr kg/hr
    Labor Cost Gas Cost Power Cost Welding Electrode Cost Flux Cost

    Labor Cost 95%

    $ $

    Welding Electrode Cost 5%

    $/m $/m $/m $/m $/m kg welded in 8 hr

    Power Cost 0% Flux Cost 0%

    Gas Cost 0%

    OUTPUT FOR Process 2 Amount of filler metal needed 1 Number of passes per joint ~ 6 Amount of shielding gas 0.31 Number of Gas Bottles Required 1 Actual welding time 0.69 Deposition Rate 3.56 Labor Cost $31.14 Welding Electrode Cost $9.06 Gas Cost $1.32 Flux Cost $ Power Cost $ 0.42 Initial Cost $41.94 0% $41.94 Final Cost Total cost per meter of weld 41.94 Filler cost per meter of weld 9.06 Flux cost per meter of weld Gas cost per meter of weld 1.32 Labor cost per meter of weld 31.14 12.83 Shift Productivity FCAW (Gas) Provides a 73.31%

    kg m^3 hr kg/hr

    Labor Cost Gas Cost Power Cost

    Welding Electrode Cost Flux Cost

    Labor Cost 74%

    Power Cost 1%

    Welding Electrode Cost 22% Flux Cost 0% Gas Cost 3%

    $/m $/m $/m $/m $/m kg welded in 8 hr Savings Relative To The

    SMAW (14" Stick)

    PERFORMANCE AND COST COMPARISONS


    180.00 160.00 140.00 120.00 100.00 Process 1 80.00 60.00 40.00 20.00 Shift Productivity Deposition Rate Total cost per meter of weld Labor cost per meter of weld Process 2

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