DETERMINING WELDING COST FOR A FILLET WELD Mark Mruczek Project: Base Material: A 516 Date: 08/07/02 Welding Engineer Company: Product Form: Plate Page: 1 of 2 Subject: Welding Cost Filler Material Welding process Used: Trade Name: Process 1 Process Leg Size (in) 0.250 Leg Size (in) 0.250 Filler material Filler material Process Process Gas Used Gas Used Amps 200 Amps Volts 21 Volts Wire Feed (in/min) 0 Wire Feed (in/min) Wire Diam. (in) 0.187 Wire Diam. (in) Total Length of Weld(ft) 10 Total Length of Weld(ft) Travel Speed (ipm) 6 Travel Speed (ipm) Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) Welder Efficiency 30% Welder Efficiency Cost Electrode($/lb) 1.3 Cost Electrode($/lb) Labor Rate ($/hr) 60 Labor Rate ($/hr) Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) Weight of gas (1 bottle) 0 Weight of gas (1 bottle) Power Cost ($/kilowatt-h $0.15 Power Cost ($/kilowatt-hr
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DETERMINING WELDING COST FOR A FILLET WELD
Mark Mruczek Project: Base Material: A 516 Date: 08/07/02Welding Engineer Company: Product Form: Plate Page: 1 of 2
Subject: Welding Cost Filler MaterialWelding process Used: Trade Name:
Process 1 Process 2Leg Size (in) 0.250 Leg Size (in) 0.250
Filler material Filler material
Process ProcessGas Used Gas Used
Amps 200 Amps 200Volts 21 Volts 21
Wire Feed (in/min) 0 Wire Feed (in/min) 190Wire Diam. (in) 0.187 Wire Diam. (in) 0.045Total Length of Weld(ft) 10 Total Length of Weld(ft) 10Travel Speed (ipm) 6 Travel Speed (ipm) 8Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 40Welder Efficiency 30% Welder Efficiency 50%Cost Electrode($/lb) 1.3 Cost Electrode($/lb) 2.5Labor Rate ($/hr) 60 Labor Rate ($/hr) 60Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $70.00Weight of gas (1 bottle) (lb) 0 Weight of gas (1 bottle) (lb) 50Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15
WELDING COST OUTPUT FOR A FILLET WELD OUTPUT FOR PROCESS 1 SMAW (14" Stick)Amount of weld wire needed 2.00 lbNumber of passes per joint ~ 1Size of fillet weld** 0.290 inAmount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 1.80 hr
Cost per ft of weld $11.11 $/ftCost per foot filler metal $0.26 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $10.82 $/ft** Size of the fillet weld is based on heat input. This information can be used to adjust your amps & volts to achieve the leg size you entered in B10OUTPUT FOR PROCESS 2 FCAW (Gas)Amount of weld wire needed 2.00 lbNumber of passes per joint ~ 1Size of fillet weld** 0.251 inAmount of shielding gas 0.00 ft^3 bottles = 1Actual welding time 0.78 hr
Joint Angle 60 Joint Angle 60Total Length of Weld(ft) 1000 Total Length of Weld(ft) 1000Travel Speed (ipm) 6 Travel Speed (ipm) 8Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 35Welder Efficiency 30% Welder Efficiency 50%Cost Electrode($/lb) 1.26 Cost Electrode($/lb) 2.25Labor Rate ($/hr) 60 Labor Rate ($/hr) 60Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $75.00Weight of gas in one bottle ( 0 Weight of gas in one bottle (l 50Power Cost ($/kilowatt-hr) $0.10 Power Cost ($/kilowatt-hr) $0.12
WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD
OUTPUT FOR SMAW (14" Stick)Amount of weld wire needed 1492.13 lbNumber of passes per joint ~ 6Amount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 1344.26 hr
Cost per ft of weld $52.06 $/ftCost per foot filler metal $1.88 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $50.01 $/ft
OUTPUT FOR FCAW (Gas)Amount of weld wire needed 1075.72 lbNumber of passes per joint ~ 9Amount of shielding gas 6196.31 ft^3 bottles = 14Actual welding time 354.07 hr
Joint Angle 45 Joint Angle 45Total Length of Weld(ft) 3.535 Total Length of Weld(ft) 3.535Travel Speed (ipm) 9 Travel Speed (ipm) 5.5Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh) 0Welder Efficiency 50% Welder Efficiency 30%Cost Electrode($/lb) 2.45 Cost Electrode($/lb) 1.3Labor Rate ($/hr) 50 Labor Rate ($/hr) 50Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle) $0.00Weight of gas in one bottle 50 Weight of gas in one bottle (l 0Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15
WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD
OUTPUT FOR FCAW (Gas)Amount of weld wire needed 38.37 lbNumber of passes per joint ~ 100Amount of shielding gas 165.52 ft^3 bottles = 1Actual welding time 9.46 hr
Cost per ft of weld $147.87 $/ftCost per foot filler metal $26.59 $/ftCost per foot of gas $5.38 $/ftCost of Labor per foot $115.05 $/ft
OUTPUT FOR SMAW (14" Stick)Amount of weld wire needed 54.00 lbNumber of passes per joint ~ 73Amount of shielding gas 0.00 ft^3 bottles = N/AActual welding time 60.00 hr
Cost per ft of weld $871.57 $/ftCost per foot filler metal $19.86 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $848.66 $/ft
Labor Cost98%
Welding Wire Cost2%
Power Cost0%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
CALCULATIONS PROCESS 1 Single-V Groovedistance "d" = 0.5625 in Process Efficiency 62% Process SMAW (14" Stick)Distance "R" = 0.6495 in Welder Efficiency 30% Bottles of gas needed N/ADistance c1 = 0.6495 in Arc Time 403.28 hr Radius of cap "r" 1.136146Distance "c" = 0.7433 in Total welding time 1344.26 hr Deposited Weld Metal Wt. 925Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3Area Cap "C" 0.0311 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.1058 lb/ft bottleArea Rectangle "A" 0.0586 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.199 lb/ft Labor Cost $ 50,006.52 Area of two Triangles "B" 0.1827 in^2 Gas Cost $0.00Weld Metal Weight "B" 0.620 lb/ft Cost Electrode $1,880.08Total Weld Metal Weight 0.9251 lb/ft Total Cost $ 52,064.05 Amount of Welding Wire 1492.13 lb Final Cost $ 7,809.61 $ 59,873.65 Deposition Rate 3.70 Lb/hr Heat Input 44Total Power Cost $177.44 Number of Passes 6
CALCULATIONS PROCESS 2 Single-V Groovedistance "d" = 0.5625 in Process Efficiency 86% Process FCAW (Gas)Distance "R" = 0.6495 in Welder Efficiency 50% Bottles of gas needed 14Distance c1 = 0.6495 in Arc Time 177.04 hr Radius of cap "r" 1.136146Distance "c" = 0.7433 in Total welding time 354.07 hr Deposited Weld Metal Wt. 925.1206Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3Area Cap "C" 0.0311 in^2 Volume of gas in one 434.78 ft^3Weld Metal Weight "C" 0.1058 lb/ft bottleArea Rectangle "A" 0.0586 in^2 Total gas needed 6196.31 ft^3Weld Metal Weight "A" 0.199 lb/ft Labor Cost $ 18,270.25 Area of two Triangles "B" 0.1827 in^2 Gas Cost $1,068.86Weld Metal Weight "B" 0.620 lb/ft Cost Electrode $2,420.37Total Weld Metal Weight 0.9251 lb/ft Total Cost $ 21,844.47 Amount of Welding Wire 1075.72 lb Final Cost $ 3,276.67 $ 25,121.13 Deposition Rate 6.08 Lb/hr Heat Input 30Total Power Cost $84.98 Number of Passes 9
CALCULATIONS PROCESS 1 Single-Bevel Groovedistance "d" = 2.15625 in Process Efficiency 86% Process FCAW (Gas)Distance "R" = 3.0494 in Welder Efficiency 50% Bottles of gas needed 1Distance c1 = 2.1563 in Arc Time 4.73 hr Radius of cap "r" 6.986Distance "c" = 2.2813 in Total welding time 9.46 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3 Deposited Weld Metal Wt. 33.00Area Cap "C" 0.1428 in^2 Volume of gas in one 434.78 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottleArea Rectangle "A" 0.2813 in^2 Total gas needed 165.52 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 406.70 Area of two Triangles "B" 2.3247 in^2 Gas Cost $19.03Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $94.01Total Weld Metal Weight 9.335 lb/ft Total Cost $ 522.72 Amount of Welding Wire 38.37 lb Final Cost $ 78.41 $ 601.13 Deposition Rate 8.11 Lb/hr Heat Input 28Total Power Cost $2.98 Number of Passes 100
CALCULATIONS PROCESS 2 Single-Bevel Groovedistance "d" = 2.15625 in Process Efficiency 62% Process SMAW (14" Stick)Distance "R" = 3.0494 in Welder Efficiency 30% Bottles of gas needed N/ADistance c1 = 2.1563 in Arc Time 18.00 hr Radius of cap "r" 6.986Distance "c" = 2.2813 in Total welding time 60.00 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3 Deposited Weld Metal Wt. 33.00Area Cap "C" 0.1428 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottleArea Rectangle "A" 0.2813 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 3,000.00 Area of two Triangles "B" 2.3247 in^2 Gas Cost $0.00Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $70.20Total Weld Metal Weight 9.335 lb/ft Total Cost $ 3,081.00 Amount of Welding Wire 54.00 lb Final Cost $ 3,543.15 Deposition Rate 3.000 Lb/hr Heat Input 38.18181818Total Power Cost $10.80 Number of Passes 73
CALCULATIONS PROCESS 1 Fillet WeldArea of Fillet Weld 0.0313 Process Efficiency 62%in2
Volume of Weld Metal 3.750 Welder Efficiency 30%0.283 Arc Time 0.541 hr
Total Weld Metal Weight 0.106 lb/ft Total welding time 1.802 hrAmount of Welding Wire 2.000 lb Heat Input 42 kJ/inDeposition Rate 3.700 lb/hr Fillet Weld Size 0.290 inDensity of gas 0 Number of Passes 1Volume of gas in one 0 Labor Cost $108.15bottle Gas Cost $0.00Total gas needed 0 Cost Electrode $2.60Bottles of gas needed N/A Total Power Cost $0.35Process SMAW (14" Stick) Total Cost $111.10
Final Cost $127.80
CALCULATIONS PROCESS 2 Fillet WeldArea of Fillet Weld 0.0313 Process Efficiency 86%Volume of Weld Metal 3.750 Welder Efficiency 50%
0.283 Arc Time 0.390 hrTotal Weld Metal Weight 0.106 lb/ft Total welding time 0.780 hrAmount of Welding Wire 2.000 lb Heat Input 31.5 kJ/inDeposition Rate 5.1310494 lb/hr Fillet Weld Size 0.251 inDensity of gas 0.116 Number of Passes 1Volume of gas in one 431.034483 Labor Cost $46.80bottle Gas Cost $2.55Total gas needed 15.5913525 Cost Electrode $5.00Bottles of gas needed 1 Total Power Cost $0.25Process FCAW (Gas) Total Cost $54.60
Final Cost $62.80
in3
Filler Density lb/in3 lb/in3
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Filler Density lb/in3 lb/in3
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ft3
SMAW (14" Stick)
inlb
FCAW (Gas)
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FCAW (Gas)
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SMAW (14" Stick)
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Alloy Density Process&Welder Eff (%) GAS Densities Cap HieghtCarbon Steel 0.283 SAW 99% 70% N/A 0 0Stainless Steel 0.29 GMAW (98Ar-2O2) 98% 50% Ar 0.111 0.03125
Nickel Alloy 0.31 GMAW (75Ar-25CO2) 96% 50% Co2 0.116 0.063GMAW CO2 93% 50% C25 0.115 0.094
Mark Mruczek: This calculation fisrt looks at the process which is stored in F15. If the process is >6 (this implies SMAW), the first IF is true and the value for deposite rate is interpolated from the table here. If F15 is < 6 (this implies a wire feed system), the second IF is true and carried out and the deposit rate is calculated from the equation Pi x radius of the wire ^2 x wire feed rate x density of the weld wirex 60
K34
Mark Mruczek: This calculation fisrt looks at the process which is stored in F15. If the process is >6 (this implies SMAW), the first IF is true and the value for deposite rate is interpolated from the table here. If F15 is < 6 (this implies a wire feed system), the second IF is true and carried out and the deposit rate is calculated from the equation Pi * radius of the wire ^2 x wire feed rate * density of the weld wire * 60
0.81250.875 Interpolation of Deposit Fillet Weld Interpolation of Deposit 0.938 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 11.000 0.000 0 110 1.8 0 01.125 0.000 0 125 2 0 0