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DETERMINACION DE LOS COSTOS DE SOLDADURA PARA UNION DE FILETE

Mark Mruczek Project: Base Material: A 516 Date:


Welding Engineer Company: Product Form: Plate Page:
Subject: Welding Cost Filler Material
Welding process Used: Trade Name:

Process 1
Longitud de pierna (in) 1.000 Leg Size (in)
Material de aporte Filler material

Proceso Process
Gas Usado Gas Used
Amps 340 Amps
Volts 31 Volts
Velocidad de alimentacion (in/min) 60 Wire Feed (in/min)
Diam. Del aporte (in) 0.045 Wire Diam. (in)
Longitud Total de Soldadura (ft) 10 Total Length of Weld(ft)
Velocidad de Soldadura (ipm) 6 Travel Speed (ipm)
Flujo de Gas (cfh) 25 Gas Flow Rate (cfh)
Eficiencia del proceso 50% Welder Efficiency
Costo del Electrodo ($/lb) 19.3 Cost Electrode($/lb)
Mano de obra ($/hr) 84 Labor Rate ($/hr)
Costo del Gas (por cilindro) $2,500.00 Cost of Gas (per bottle)
Peso del gas (1 cilindro) (lb) 500 Weight of gas (1 bottle) (lb)
Costo de la electricidad ($/kilowatt-hr) $1.50 Power Cost ($/kilowatt-hr)
WELDING COST OUTPUT FOR A FILLET WELD
OUTPUT FOR PROCESS 1 GMAW (98Ar-2O2)
Amount of weld wire needed 18.00 lb
Number of passes per joint ~ 5
Size of fillet weld** 0.459 in
Amount of shielding gas 277.72 ft^3 bottles = 1
Actual welding time 22.22 hr

Labor Cost $1,866.30


Labor Cost; 73%
Welding Wire Cost $347.40
Gas Cost $159.70 Welding Wire Cost
Power Cost $175.65
Initial Cost $2,549.05
Final Cost $2,931.45 Gas Cost; 6%

Power Cost; 7%
Cost per ft of weld $254.91 $/ft
Cost per foot filler metal $34.74 $/ft
Cost per foot of gas $15.97 $/ft
Cost of Labor per foot $186.63 $/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 B10
OUTPUT FOR PROCESS 2 FCAW (Gas)
Amount of weld wire needed 2.00 lb
Number of passes per joint ~ 1
Size of fillet weld** 0.251 in
Amount of shielding gas 0.00 ft^3 bottles = 1
Actual welding time 0.78 hr Labor Co
Labor Cost; 86%
Welding
Labor Cost $46.80
Welding Wire Cost $5.00 Gas Cos
Gas Cost $2.55 Power C
Power Cost $0.25
Initial Cost $54.60
Final Cost $62.80 Welding Wire Cost; 9%
Gas Cost; 5%
Power Cost; 0%
Cost per ft of weld $5.46 $/ft
Cost per foot filler metal $0.50 $/ft
Cost per foot of gas $0.26 $/ft
Power Cost; 0%

Cost of Labor per foot $4.68 $/ft


08/07/02
1 of 2

Process 2
0.250

200
21
190
0.045
Total Length of Weld(ft) 10
8
Gas Flow Rate (cfh) 40
50%
Cost Electrode($/lb) 2.5
60
Cost of Gas (per bottle) $70.00
Weight of gas (1 bottle) (lb) 50
Power Cost ($/kilowatt-hr) $0.15
Labor Cost
Welding Wire Cost
Gas Cost
Labor Cost; 73%
Power Cost
Welding Wire Cost; 14%

Gas Cost; 6%

Power Cost; 7%

Labor Cost
Labor Cost; 86%
Welding Wire Cost
Gas Cost
Power Cost

Welding Wire Cost; 9%


Gas Cost; 5%
Power Cost; 0%
Power Cost; 0%
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 2
Thickness (in) 0.625 Thickness (in) 0.625
Height of "h" (in) 0.031 Height of "h" (in) 0.063
Root Opening (in) 0.063 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 280 Amps
Volts 27 Volts
Wire Feed (in/min) 0 Wire Feed (in/min)
Wire Diam. (in) 0.094 Wire Diam. (in)
Joint Angle 70 Joint Angle
Total Length of Weld(ft) 1.9 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 Efficiency
Cost Electrode($/lb) 1.26 Cost Electrode($/lb)
Labor Rate ($/hr) 60 Labor Rate ($/hr)
Cost of Gas (per bottle) $0.00 Cost of Gas (per bottle)
Weight of gas in one bottle (lb) 0 Weight of gas in one bottle (l
Power Cost ($/kilowatt-hr) $0.10 Power Cost ($/kilowatt-hr)
WELDING COST OUTPUT FOR A SINGLE-V GROOVE WELD

OUTPUT FOR SMAW (14" Stick)


Amount of weld wire needed 2.90 lb
Number of passes per joint ~ 4 Labor Cost
Amount of shielding gas 0.00 ft^3 bottles = N/A Welding Wire Cost
Actual welding time 1.34 hr Labor Cost; 93% Gas Cost
Power Cost
Labor Cost $49.89
Welding Wire Cost $3.65
Gas Cost $0.00
Power Cost $0.30
Initial Cost $53.84
Final Cost $61.92
Welding Wire Cost; 7%
Power Cost; 1%
Cost per ft of weld $28.34 $/ft
Cost per foot filler metal $1.92 $/ft
Cost per foot of gas $0.00 $/ft
Cost of Labor per foot $26.26 $/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 Welding Wire Cost; 11% Gas Cost; 5%
Actual welding time 394.16 hr Power Cost; 0%

Labor Cost $20,338.90


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

Cost per ft of weld $24.32 $/ft


Cost per foot filler metal $2.69 $/ft
Cost per foot of gas $1.19 $/ft
Labor Cost; 84%
Cost of Labor per foot $20.34 $/ft
Labor Cost; 84%
Process 2

200
20
225
0.05
60
1000
8
35
50%
2.25
60
$75.00
50
$0.12
Labor Cost
Welding Wire Cost

Labor Cost; 93% Gas Cost


Power Cost

Welding Wire Cost; 7%


Power Cost; 1%

Welding Wire Cost; 11% Gas Cost; 5%


Power Cost; 0%

Labor Cost
Welding Wire Cost
Gas Cost
Power Cost

Labor Cost; 84%


Labor Cost; 84%
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 Process 2
Thickness (in) 2.25 Thickness (in) 2.25
Height of "h" (in) 0.09375 Height of "h" (in) 0.09375
Root Opening (in) 0.125 Root Opening (in) 0.125
Root Face(in) 0.09375 Root Face(in) 0.09375

Filler material Filler material

Process Process
Gas Used Gas Used
Amps 200 Amps
Volts 21 Volts
Wire Feed (in/min) 225 Wire Feed (in/min)
Wire Diam. (in) 0.052 Wire Diam. (in)
Joint Angle 45 Joint Angle
Total 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 Efficiency
Cost Electrode($/lb) 2.45 Cost Electrode($/lb)
Labor Rate ($/hr) 50 Labor Rate ($/hr)
Cost of Gas (per bottle) $50.00 Cost of Gas (per bottle)
Weight of gas in one bottle 50 Weight of gas in one bottle (l
Power Cost ($/kilowatt-hr) $0.15 Power Cost ($/kilowatt-hr)
WELDING COST OUTPUT FOR A SINGLE-BEVEL GROOVE WELD

OUTPUT FOR FCAW (Gas)


Amount of weld wire needed 38.37 lb
Number of passes per joint ~ 100
Amount of shielding gas 165.52 ft^3 bottles = 1 Power Cost; 1%
Gas Cost; 4%
Actual welding time 9.46 hr
Welding Wire Cost; 18%
Labor Cost $406.70
Welding Wire Cost $94.01 Labor Cost
Gas Cost $19.03 Welding Wire Cost
Power Cost $2.98 Gas Cost
Initial Cost $522.72 Power Cost
Final Cost $ 601.13
Labor Cost; 78%

Cost per ft of weld $147.87 $/ft


Cost per foot filler metal $26.59 $/ft
Cost per foot of gas $5.38 $/ft
Cost of Labor per foot $115.05 $/ft

OUTPUT FOR SMAW (14" Stick)


Amount of weld wire needed 54.00 lb
Number of passes per joint ~ 73
Amount of shielding gas 0.00 ft^3 bottles = N/A Labor Cost; 98%
Actual welding time 60.00 hr

Labor Cost $3,000.00


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

Power Cost; 0% Welding Wire Cost; 2%


Cost per ft of weld $871.57 $/ft
Cost per foot filler metal $19.86 $/ft
Cost per foot of gas $0.00 $/ft
Power Cost; 0% Welding Wire Cost; 2%

Cost of Labor per foot $848.66 $/ft


Process 2

175
20
0
0.188
45
3.535
5.5
0
30%
1.3
50
$0.00
0
$0.15
Gas Cost; 4% Power Cost; 1%

Welding Wire Cost; 18%

Labor Cost
Welding Wire Cost
Gas Cost
Power Cost

Labor Cost; 78%

Labor Cost; 98%

Labor Cost
Welding Wire Cost
Gas Cost
Power Cost

Power Cost; 0% Welding Wire Cost; 2%


Power Cost; 0% Welding Wire Cost; 2%
CALCULATIONS PROCESS 1 Single-V Groove
distance "d" = 0.5625 in Process Efficiency 62% Process SMAW (14" Stick)
Distance "R" = 0.6867 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 0.7877 in Arc Time 0.40 hr Radius of cap "r" 2.907207
Distance "c" = 0.8502 in Total welding time 1.34 hr Deposited Weld Metal Wt. 2
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3
Area Cap "C" 0.0177 in^2 Volume of gas in one 0.00 ft^3
Weld Metal Weight "C" 0.0602 lb/ft bottle
Area Rectangle "A" 0.0391 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.133 lb/ft Labor Cost $ 49.89
Area of two Triangles "B" 0.2215 in^2 Gas Cost $0.00
Weld Metal Weight "B" 0.752 lb/ft Cost Electrode $3.65
Total Weld Metal Weight 0.9453 lb/ft Total Cost $ 53.84
Amount of Welding Wire 2.90 lb Final Cost $ 8.08 $ 61.92
Deposition Rate 7.20 Lb/hr Heat Input 76
Total Power Cost $0.30 Number of Passes 4

CALCULATIONS PROCESS 2 Single-V Groove


distance "d" = 0.5625 in Process Efficiency 86% Process FCAW (Gas)
Distance "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" 1.438578
Distance "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 $2,694.42
Total 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 30
Total Power Cost $94.60 Number of Passes 10
CALCULATIONS PROCESS 1 Single-Bevel Groove
distance "d" = 2.15625 in Process Efficiency 86% Process FCAW (Gas)
Distance "R" = 3.0494 in Welder Efficiency 50% Bottles of gas needed 1
Distance 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 45
Filler 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^3
Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 165.52 ft^3
Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 406.70
Area of two Triangles "B" 2.3247 in^2 Gas Cost $19.03
Weld 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 28
Total Power Cost $2.98 Number of Passes 100

CALCULATIONS PROCESS 2 Single-Bevel Groove


distance "d" = 2.15625 in Process Efficiency 62% Process SMAW (14" Stick)
Distance "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 45
Filler 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^3
Weld Metal Weight "C" 0.4848 lb/ft bottle
Area Rectangle "A" 0.2813 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.955 lb/ft Labor Cost $ 3,000.00
Area of two Triangles "B" 2.3247 in^2 Gas Cost $0.00
Weld 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 38.18181818
Total Power Cost $10.80 Number of Passes 73

CALCULATIONS PROCESS 1 Fillet Weld


Area of Fillet Weld 0.5000 in2 Process Efficiency 98%
Volume of Weld Metal 60.000 in3 Welder Efficiency 50%
Filler Density lb/in3 0.283 lb/in3 Arc Time 11.109 hr
Total Weld Metal Weight 1.698 lb/ft Total welding time 22.218 hr
Amount of Welding Wire 18.000 lb Heat Input 105.4 kJ/in
Deposition Rate 1.620 lb/hr Fillet Weld Size 0.459 in
Density of gas 0.115 lb/ft3 Number of Passes 5
Volume of gas in one 4347.82609 ft3 Labor Cost $1,866.30
bottle Gas Cost $159.70
Total gas needed 277.720967 ft3 Cost Electrode $347.40
Bottles of gas needed 1 Total Power Cost $175.65
Process GMAW (98Ar-2O2) Total Cost $2,549.05
Final Cost $2,931.45

CALCULATIONS PROCESS 2 Fillet Weld


Area of Fillet Weld 0.0313 in2 Process Efficiency 86%
Volume of Weld Metal 3.750 in 3
Welder Efficiency 50%
Filler Density lb/in3 0.283 lb/in3 Arc Time 0.390 hr
Total Weld Metal Weight 0.106 lb/ft Total welding time 0.780 hr
Amount of Welding Wire 2.000 lb Heat Input 31.5 kJ/in
Deposition Rate 5.1310494 lb/hr Fillet Weld Size 0.251 in
Density of gas 0.116 lb/ft3 Number of Passes 1
Volume of gas in one 431.034483 ft 3
Labor Cost $46.80
bottle Gas Cost $2.55
Total gas needed 15.5913525 ft 3
Cost Electrode $5.00
Bottles of gas needed 1 Total Power Cost $0.25
Process FCAW (Gas) Total Cost $54.60
Final Cost $62.80
SMAW (14" Stick)

in
lb

FCAW (Gas)

in
lb
FCAW (Gas)

in

lb

SMAW (14" Stick)

in

lb
Alloy Density Process&Welder Eff (%) GAS Densities Cap Hieght
Carbon Steel 0.283 SAW 99% 70% N/A 0 0
Stainless 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 0.063
GMAW CO2 93% 50% C25 0.115 0.094
1 1 FCAW (Gas) 86% 50% 1 4 Single V 0.125
1 1 FCAW (Self Shield) 78% 50% 4 1 Single Bev 0.25
1 1 SMAW (12" Stick) 59% 30% 4 3 Fillet 0.375
SMAW (14" Stick) 0.62 30% 1
SMAW (18" Stick) 66% 30% 3
8 5 Sing-V 3
5 8 Sing-Bev 3
2 5 Fillet 4
Interpolation of Deposit Single_V Interpolation of Deposit 3
Rate Process 1 5 Deposition Rates SMAW 8 Rate Process 1
0.000 0 110 1.8 0 0.000
0.000 0 125 2 0 0.000
0.000 0 150 2.6 0 0.000
0.000 0 175 3 0 0.000
6.076 200 200 3.7 0 0.000
0.000 0 225 4.2 0 0.000
0.000 0 275 7 275 7.200
0.000 0 325 9 0 0.000
6.076 400 10 7.200

Weld Size
0.125 Interpolation of Deposit Single Bevel Interpolation of Deposit
0.1875 Rate Process 1 8 Deposition Rates SMAW 5 Rate Process 1
0.250 0.000 0 110 1.8 0 0.000
0.313 0.000 0 125 2 0 0.000
0.375 0.000 0 150 2.6 0 0.000
0.438 3.000 175 175 3 0 0.000
0.500 0.000 0 200 3.7 200 8.114
0.5625 0.000 0 225 4.2 0 0.000
0.625 0.000 0 275 7 0 0.000
0.688 0.000 0 325 9 0 0.000
0.750 3.000 400 10 8.114
0.8125
0.875 Interpolation of Deposit Fillet Weld Interpolation of Deposit
0.938 Rate Process 1 2 Deposition Rates SMAW 5 Rate Process 1
1.000 0.000 0 110 1.8 0 0
1.125 0.000 0 125 2 0 0
1.25 0.000 0 150 2.6 0 0
1.375 0.00 0 175 3 0 0
1.5 0.000 0 200 3.7 200 5.131
1.5625 0.000 0 225 4.2 0 0
1.625 0.000 0 275 7 0 0
1.75 1.620 325 325 9 0 0
1.8125 1.620 400 10 5.131
1.875
2
2.125
2.25
2.375
2.5
2.5625
2.625
2.75
2.8125
2.875
3
3.125
3.25
3.375
3.5
3.5625
3.625
3.75
3.8125
Single V 9 9
Single Bevel 27 27
Fillet Weld 15 3
2
2
2
3
4
3