Mark Mruczek

Welding Engineer
Mruczek Welding Engineering
Johnstown PA, 15905

Base Material:
Product Form:
Subject:
Pipe Weld Design
Filler Material
Welding process(es) Used: GTAW /SMAW
Trade Name:
Notes: process 1 = root pass, process 2 = Fill and cap passes
Project:
Company:

DEMO
N/A

Please choose units before you enter data into the fields below
Process 1 GTAW Root Pass
Thickness (in)
6 mm
Height of "h" (in)
1.588 mm
Root Opening (in)
4 mm
Root Face(in)
2.3813 mm
Filler material
Process
Gas Used
Amps
Volts
Wire Feed (m/min)
Electrode Diam. (mm)
Joint Angle (deg)
Total Weld Length (m)
Travel Speed (m/min)
Gas Flow Rate (L/min)
Welder Efficiency
Cost Electrode ($/kg)
Labor Rate
Cost of Gas
Gas Cylinder Size (m^3)
Power Cost
Cost of Flux ($/kg)

Units =
Last

CS
Pipe
E7018
Lincoln

Date:
Page:

03/09/07
1 of 2

Process 2 SMAW Fill Passes

Thickness (in)
9.11
Height of "h" (in)
1.588
Root Opening (in)
4
Root Face(in)
2.3813

mm

mm
mm
mm

Filler material
Process
Gas Used

95
20
0
2.40000
0
0.24
0.1016
17

A
V
m/min
mm
deg
m

m/min
L/min

!"

25.59
50.00
40.00
9.34428
0.20
2
2

$/kg
$/hr
$/bottle
m^3
$/kwh
$/kg

Scroll Down To See Results

Amps
110
Volts
15
Wire Feed (m/min)
0
Electrode Diam. (mm)
3.2
Joint Angle (deg)
70
Total Weld Length (ft)
0.27
Travel Speed (m/min)
0.1651
Gas Flow Rate (L/min)
0
#$"
Welder Efficiency
Cost Electrode ($/kg)
19.84
Labor Rate
50.00
Cost of Gas
Gas Cylinder Size (m^3)
0.00
Power Cost
0.20
Cost of Flux ($/kg)
-

Units =
Last

A
V
m/min
mm
deg
m

m/min
L/min
$/kg
$/hr
$/bottle
m^3
$/kwh
$/kg

OUTPUT FOR Process 1 GTAW Root Pass

Amount of filler metal needed
0.06 kg
Number of passes per joint ~
2
Amount of shielding gas
1.09 m^3
Number of Gas Bottles Required
1
Actual welding time
4.41 hr
Deposition Rate
0.05 kg/hr
Labor Cost
$220.37
Welding Electrode Cost
$1.51
Gas Cost
$4.67
Flux Cost
$
Power Cost
$
0.42
$226.98
Initial Cost
$"
Final Cost
$226.98
Total cost per meter of weld
934.07 $/m
Filler cost per meter of weld
6.23 $/m
Flux cost per meter of weld
$/m
Gas cost per meter of weld
19.24 $/m
Labor cost per meter of weld
906.87 $/m
Shift Productivity
0.10 kg welded in 8 hr
OUTPUT FOR Process 2 SMAW Fill Passes
Amount of filler metal needed
0.284 kg
Number of passes per joint ~
9
Amount of shielding gas
0.00 m^3
Number of Gas Bottles Required
N/A
Actual welding time
0.61 hr
Deposition Rate
1.00 kg/hr
Labor Cost
$30.30
Welding Electrode Cost
$5.63
Gas Cost
$Flux Cost
$
Power Cost
$
0.06
$35.99
Initial Cost
$"
Final Cost
$35.99
Total cost per meter of weld
131.85 $/m
Filler cost per meter of weld
20.63 $/m
Flux cost per meter of weld
$/m
Gas cost per meter of weld
$/m
Labor cost per meter of weld
111.00 $/m
Shift Productivity
2.39 kg welded in 8 hr
SMAW (14" Stick) Provides a
84.14%
Savings Relative To The GTAW

Labor Cost
Gas Cost
Power Cost

Welding Electrode Cost

Flux Cost

Labor Cost
97%

Power Cost
0%
Flux Cost
0%

Gas Cost
2%

Labor Cost
Gas Cost
Power Cost

Welding
Electrode Cost
1%

Welding Electrode Cost

Flux Cost

Labor Cost
84%

Power Cost
0%
Flux Cost
0%

Gas Cost
0%

Welding
Electrode Cost
16%