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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 2Leg Size (in) 0.250 Leg Size (in) 0.250

Filler material Filler material

Process ProcessGas Used Gas Used

Amps 200 Amps 200

Volts 21 Volts 21Wire 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) 8

Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh) 40Welder 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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DETERMINING WELDING COST FOR A SINGLE-V GROOVE 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 E7018

Welding process Used: Trade Name:

Process 1 Process

Thickness (in) 0.438 Thickness (in) 0.625Height of "h" (in) 0.125 Height of "h" (in) 0.063Root Opening (in) 0.125 Root Opening (in) 0.094

Root Face(in) 0.063 Root Face(in) 0.063

Filler material Filler material

Process Process

Gas Used Gas Used

Amps 130 Amps

Volts 27 Volts

Wire Feed (in/min) 0 Wire Feed (in/min)

Wire Diam. (in) 0.1576 Wire Diam. (in)

Joint Angle 70 Joint Angle

Total Length of Weld(ft) 8.9 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 EfficiencyCost Electrode($/lb) 1.26 Cost Electrode($/lb)

Labor Rate ($/hr) 60 Labor Rate ($/hr)

Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle)

Weight of gas in one bottle ( 0 Weight of gas in one bottle (l

Power Cost ($/kilowatt-hr) $0.10 Power Cost ($/kilowatt-hr)

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 WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

OUTPUT FOR SMAW (12" Stick)

 Amount of weld wire needed 10.70 lbNumber of passes per joint ~ 6 Amount of shielding gas 0.00 ft^3 bottles = N/A Actual welding time 16.83 hr 

Labor Cost $595.66Welding Wire Cost $13.48Gas Cost $0.00Power Cost $1.77Initial Cost $610.91

Final Cost $702.55

Cost per ft of weld $68.64 $/ftCost per foot filler metal $1.52 $/ftCost per foot of gas $0.00 $/ftCost of Labor per foot $66.93 $/ft

OUTPUT FOR FCAW (Gas)

 Amount of weld wire needed 1197.52 lb

Number of passes per joint ~ 10 Amount of shielding gas 6897.88 ft^3 bottles = 16 Actual welding time 394.16 hr 

Labor Cost $20,338.90Welding Wire Cost $2,694.42Gas Cost $1,189.88Power Cost $94.60Initial Cost $24,317.80Final Cost 27,965.47$

Cost per ft of weld $24.32 $/ftCost per foot filler metal $2.69 $/ftCost per foot of gas $1.19 $/ft

Labor Cost84%

Welding Wire Cost11%

Gas Cost5% Power Cost

0%

Labor C

Welding

Gas Co

Power

Labor Cost98%

Welding Wire Cost2%

Gas Cost0%

Power Cost0%

Labor

Weldin

Gas Co

Power

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200

20

2250.0560

10008

35

50%2.2560

$75.0050

$0.12

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  ost

 Wire Cost  st

  ost

 

ost

 Wire Cost

  st

  ost

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DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD

Mark Mruczek  Project: Base Material:  A 516 Date: 05/22/02

Welding Engineer  Company: Product Form: Plate Page: 1 of 2

 Subject: Welding Cost Filler Material E7018

Welding process Used: SMAW + GMAW Trade Name: Lincoln

Process 1 ProcessThickness (in) 2.25 Thickness (in) 2.25

Height of "h" (in) 0.09375 Height of "h" (in) 0.09375Root Opening (in) 0.125 Root Opening (in) 0.125

Root Face(in) 0.09375 Root Face(in) 0.09375

Filler material Filler material

Process ProcessGas Used Gas Used

Amps 200 AmpsVolts 21 Volts

Wire Feed (in/min) 225 Wire Feed (in/min)Wire Diam. (in) 0.052 Wire Diam. (in)

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)

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 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 ~ 100

 Amount of shielding gas 165.52 ft^3 bottles = 1 Actual welding time 9.46 hr 

Labor Cost $406.70Welding Wire Cost $94.01Gas Cost $19.03Power Cost $2.98Initial Cost $522.72Final Cost 601.13$

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 ~ 73 Amount of shielding gas 0.00 ft^3 bottles = N/A

 Actual welding time 60.00 hr 

Labor Cost $3,000.00Welding Wire Cost $70.20Gas Cost $0.00Power Cost $0.28Initial Cost $3,081.00Final Cost 3,543.15$

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 Cost78%

Welding Wire Cost18%

Gas Cost4% Power Cost

0%

Labor

Weldin

Gas Co

Power

Labor Cost98%

Welding WireCost2%

Gas Cost0%

Power Cost0%

Labor

Weldi

Gas C

Power

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175

20

00.188

45

3.5355.5

030%

1.350

$0.000

$0.15

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  ost

g Wire Cost

  st Cost

 Costng Wire Cost

  ost

r Cost

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CALCULATIONS PROCESS 1 Single-V Groove

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

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CALCULATIONS PROCESS 1 Single-Bevel Groove

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  

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  " Stick)

inlb

  s)

inlb

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  s)

in

lb

  " Stick)

in

lb

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GAS Densities

Carbon Steel 0.283 SAW 99% 70% N/A 0

Stainless Steel 0.29 GMAW (98Ar-2O2) 98% 50% Ar 0.111Nickel Alloy 0.31 GMAW (75Ar-25CO2) 96% 50% Co2 0.116

GMAW CO2 93% 50% C25 0.1151 1 FCAW (Gas) 86% 50% 1 4 Single V1 1 FCAW (Self Shield) 78% 50% 4 1 Single Bev

1 1 SMAW (12" Stick) 59% 30% 1 3 FilletSMAW (14" Stick) 0.62 30%SMAW (18" Stick) 66% 30%

7 5 Sing-V5 8 Sing-Bev

8 5 Fillet

Interpolation of Deposit Single_V Interpolation of DepositRate Process 1 5 Deposition Rates SMAW 7 Rate Process 1

0.000 0 110 1.8 0 0.0000.000 0 125 2 125 2.1200.000 0 150 2.6 0 0.0000.000 0 175 3 0 0.0006.076 200 200 3.7 0 0.0000.000 0 225 4.2 0 0.000

0.000 0 275 7 0 0.0000.000 0 325 9 0 0.0006.076 400 10 2.120

Weld Size

0.125 Interpolation of Deposit Single Bevel Interpolation

0.1875 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process0.250 0.000 0 110 1.8 0 0.0000.313 0.000 0 125 2 0 0.0000.375 0.000 0 150 2.6 0 0.0000.438 3.000 175 175 3 0 0.0000.500 0.000 0 200 3.7 200 8.114

0.5625 0.000 0 225 4.2 0 0.0000.625 0.000 0 275 7 0 0.0000.688 0.000 0 325 9 0 0.0000.750 3.000 400 10 8.114

0.81250.875 Interpolation of Deposit Fillet Weld Interpolation0.938 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process

Alloy Density Process&Welder Eff (%)

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1.000 0.000 0 110 1.8 0 0

1.125 0.000 0 125 2 0 01.25 0.000 0 150 2.6 0 0

1.375 0.00 0 175 3 0 01.5 3.700 200 200 3.7 200 5.131

1.5625 0.000 0 225 4.2 0 01.625 0.000 0 275 7 0 0

1.75 0.000 0 325 9 0 01.8125 3.700 400 10 5.131

1.8752

2.125

2.252.375

2.52.56252.625

2.75

2.81252.875

3

3.1253.25

3.3753.5

3.56253.625

3.753.8125

Single V 6 9Single Bevel 27 27Fillet Weld 3 3

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Cap Hieght

0

0.03125

0.0630.094

0.1250.25

0.3754 4

3 23 23 3

4 4

3 3

 of Deposit

1

 of Deposit1

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