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:

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

Cost of Flux ($/kg)

Units =
Last

N/A

$/kg
2
2

Date:
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For This Sheet

10/22/07
1 of 3
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Metric Units

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

SMAW (14" Stick)

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

CS
Plate
E71T-1
Lincoln

14
1
2
2

mm

mm
mm
mm

Carbon Steel
FCAW (Gas)
75Ar-25C02

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)

Units =
Last

$/kg
2

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

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
95%

Welding
Electrode Cost
5%

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

kg
m^3
hr
kg/hr

Power Cost
0%
Flux Cost
0%

Labor Cost
Gas Cost
Power Cost

Welding Electrode Cost

Flux Cost

Labor Cost
74%

Welding
Electrode Cost
22%

Power Cost
1%

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

Gas Cost
0%

Flux Cost
0%

SMAW (14" Stick)

Gas Cost
3%

PERFORMANCE AND COST COMPARISONS

180.00
160.00
140.00
120.00
100.00
Process 1
Process 2

80.00
60.00
40.00
20.00
Shift Productivity

Deposition Rate

Total cost per

meter of weld

Labor cost per

meter of weld