8/10/2019 Weld Cost Spreadsheet http://slidepdf.com/reader/full/weld-cost-spreadsheet 1/25 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 2 Leg Size (in) 0.250 Leg Size (in) 0.250 Filler material Filler material Process Process Gas Used Gas Used Amps 200 Amps 200 Volts 21 Volts 21 Wire Feed (in/min) 0 Wire Feed (in/min) 190 Wire Diam. (in) 0.187 Wire Diam. (in) 0.045 Total Length of Weld(ft) 10 Total Length of Weld(ft) 10 Travel Speed (ipm) 6 Travel Speed (ipm) 8 Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 40 Welder Efficiency 30% Welder Efficiency 50% Cost Electrode($/lb) 1.3 Cost Electrode($/lb) 2.5 Labor Rate ($/hr) 60 Labor Rate ($/hr) 60 Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle) $70.00 Weight of gas (1 bottle) (lb) 0 Weight of gas (1 bottle) (lb) 50 Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr) $0.15
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Joint Angle 45 Joint AngleTotal Length of Weld(ft) 3.535 Total Length of Weld(ft)Travel Speed (ipm) 9 Travel Speed (ipm)Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh)
Welder Efficiency 50% Welder EfficiencyCost Electrode($/lb) 2.45 Cost Electrode($/lb)Labor Rate ($/hr) 50 Labor Rate ($/hr)Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle)Weight of gas in one bottle 50 Weight of gas in one bottle (lPower Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr)
distance "d" = 0.375 in Process Efficiency 59% Process SMAW (12Distance "R" = 0.4578 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 0.5252 in Arc Time 5.05 hr Radius of cap "r" 0.485202Distance "c" = 0.6502 in Total welding time 16.83 hr Deposited Weld Metal Wt. 6
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3
Area Cap "C" 0.0557 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.1893 lb/ft bottle
Area Rectangle "A" 0.0547 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.186 lb/ft Labor Cost 595.66$
Area of two Triangles "B" 0.0985 in^2 Gas Cost $0.00Weld Metal Weight "B" 0.334 lb/ft Cost Electrode $13.48
Total Weld Metal Weight 0.7094 lb/ft Total Cost 610.91$ Amount of Welding Wire 10.70 lb Final Cost 91.64$ 702.55$
Deposition Rate 2.12 Lb/hr Heat Input 35Total Power Cost $1.77 Number of Passes 6
CALCULATIONS PROCESS 2 Single-V Groove
distance "d" = 0.5625 in Process Efficiency 86% Process FCAW (GaDistance "R" = 0.6495 in Welder Efficiency 50% Bottles of gas needed 16
Distance c1 = 0.7451 in Arc Time 197.08 hr Radius of cap "r" 1.438578Distance "c" = 0.8388 in Total welding time 394.16 hr Deposited Weld Metal Wt. 1029.867
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3 Area Cap "C" 0.0351 in^2 Volume of gas in one 434.78 ft^3
Weld Metal Weight "C" 0.1192 lb/ft bottle Area Rectangle "A" 0.0586 in^2 Total gas needed 6897.88 ft^3
Weld Metal Weight "A" 0.199 lb/ft Labor Cost 20,338.90$ Area of two Triangles "B" 0.2096 in^2 Gas Cost $1,189.88
Weld Metal Weight "B" 0.712 lb/ft Cost Electrode $2,694.42Total Weld Metal Weight 1.0299 lb/ft Total Cost 24,317.80$
Amount of Welding Wire 1197.52 lb Final Cost 3,647.67$ 27,965.47$Deposition Rate 6.08 Lb/hr Heat Input 30Total Power Cost $94.60 Number of Passes 10
distance "d" = 2.15625 in Process Efficiency 86% Process FCAW (Ga
Distance "R" = 3.0494 in Welder Efficiency 50% Bottles of gas needed 1Distance c1 = 2.1563 in Arc Time 4.73 hr Radius of cap "r" 6.986
Distance "c" = 2.2813 in Total welding time 9.46 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0.115 lb/ft^3 Deposited Weld Metal Wt. 33.00
Area Cap "C" 0.1428 in^2 Volume of gas in one 434.78 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 165.52 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost 406.70$
Area of two Triangles "B" 2.3247 in^2 Gas Cost $19.03Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $94.01
Total Weld Metal Weight 9.335 lb/ft Total Cost 522.72$ Amount of Welding Wire 38.37 lb Final Cost 78.41$ 601.13$
Deposition Rate 8.11 Lb/hr Heat Input 28Total Power Cost $2.98 Number of Passes 100
CALCULATIONS PROCESS 2 Single-Bevel Groove
distance "d" = 2.15625 in Process Efficiency 62% Process SMAW (14Distance "R" = 3.0494 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 2.1563 in Arc Time 18.00 hr Radius of cap "r" 6.986
Distance "c" = 2.2813 in Total welding time 60.00 hr Beta 45Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3 Deposited Weld Metal Wt. 33.00
Area Cap "C" 0.1428 in^2 Volume of gas in one 0.00 ft^3Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 0.00 ft^3Weld Metal Weight "A" 0.955 lb/ft Labor Cost 3,000.00$
Area of two Triangles "B" 2.3247 in^2 Gas Cost $0.00Weld Metal Weight "B" 7.895 lb/ft Cost Electrode $70.20
Total Weld Metal Weight 9.335 lb/ft Total Cost 3,081.00$ 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 Weld
Area of Fillet Weld 0.0313 in2
Process Efficiency 62%
Volume of Weld Metal 3.750 in3Welder Efficiency 30%
Filler Density lb/in3
0.283 lb/in3
Arc Time 0.541 hr Total Weld Metal Weight 0.106 lb/ft Total welding time 1.802 hr