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:
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10/22/07 1 of 3
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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)

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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