BASIC WELDING FILLER METAL TECHNOLOGY A Correspondence Course LESSON IX ESTIMATING AND COMPARING WELD METAL COSTS Cutting Products 7 ESAB__—_ ESAB Welding & 7Section Nr. a4 9.2 924 92.2 92.3 924 925 9.2.6 927 928 9.2.9 92.40 93 94 944 942 95 9.6 9.64 97 98 TABLE OF CONTENTS LESSON IX ESTIMATING AND COMPARING WELD METAL COSTS Section Title Introduction Factors For Cost Formulas Labor & Overhead Deposition Rate . Operating Factor Deposition Efficiency Deposition Efficiency of Coated Electrodes Efficiency of Flux Cored Wires Efficiency of Solid Wires for GMAW. Efficiency of Solid Wires for SAW. Cost of Electrodes, Wires, Gases and Fiux Cost of Power Deposition Data Tables Cost Calculations Calculating the Cost Per Pound of Deposited Weld Metal Calculating the Cost Per Foot Of Deposited Weld Metal Cost Calculations - Example 2 Comparing Weld Metal Costs Example 3 Other Useful Formulas Amortization of Equipment Costs Appendix A Lesson IX Test Questions Appendix B Problem 4 Worksheet Appendix C Problem 2 Worksheet Page WANN oon e une 12 12 44 415 17 419 20 2 22 26 27LESSON IX ESTIMATING AND COMPARING WELD METAL COSTS 9.1_ INTRODUCTION Estimating the costs of depositing weld metal can be a difficulttask because of the many variables involved. Design engineers must specify the type and size of weld joint to withstand the loads that the weldment must bear. The welding engineer must select the welding process, and bpe of filler metal that will provide the required welds at the least possible cost. With wages and the cost of operations rising, selection of the process that deposits weld metal most expediently must be carefully considered. Labor and overhead account for approxi- mately 85% of the total welding cost. 9.1.0.1 Welding costs may be divided into two categories; the “fixed” costs involved regard- less ofthe filer metal or welding process selected, and those related to a specific welding process. Fixed casts entail material handling, joint preparation, fiduring, tacking, preheating, weld clean-up and inspection. Although some of these items will be affected by the process: and filler metal chosen, they are a necessary part of practically all welding operations. Calcu- lating these costs is best leftta the manufacturer since they will depend upon his capabilities and equipment. The cost of actually depositing the weld metal however, will vary considerably with the filler metal and welding process selected. This cost element is influenced by the user's labor and overhead rates, deposition rate and efficiency of the filler metal, operating factor, and cost of materials and power. 9.1.0.2 This lesson will cover cost estimating for steel weldments praduced by the four most common arc welding processes in use today. shielded metal-arc welding, gas metal-arc welding, flux cored arc welding and submerged arc welding. Gas tungsten arc welding will not be considered here because the variables, such as deposition rate and efficiency, are depen- dent on operator technique, stub use, ete. The GTAW process is a relatively costly method of depositing weld metal, and is usually chosen for weld quality or material thickness and campo- sition limitations, rather than economy. 9.1.0.3 Large firms will frequently conduct their own deposition tests and time studies to determine welding casts, but many smaller shops do not know the actual cost of depositing weld metal 9.1.0.4 — Inestimating welding costs, all attempts should be made to work with accurate data, which in same cases is difficult to secure. For this reason, this lesson contains charts, graphsLESSON IX and tables that provide average values that you may use. Electrode manufacturers will usually supply the deposition data you need through their Technical Services Department, ifitis not already published in their literature. 9.2_ FACTORS FOR COST FORMULAS 9.24 Labor and Overhead - Labor and overhead may be considered jointly in your calculations. Labor is the welder's hourly rate of pay including wages and benefits. Overhead includes allocated portions of plant operating and maintenance costs. Weld shops in manu- facturing plants normally have established labor and overhead rates for each department. Labor and overhead rates can vary greatly from plant to plant, and also with location. Figure 4 shows how labor and overhead may vary and suggests an average value ta use in your calcu- lations when the actual value Is unknown. HOURLY WELDING LABOR & OVERHEAD RATES. Small Shops $19.00 te $26.00/he Lerge Shops $25.00 ta $£0,00/hr Average $30.00/hr APPROXIMATE LABOR AND GVERHEAD RATES: FIGURE 1 9.2.2 Deposition Rate - The depasition rate is the rate that weld metal can be deposited by a given electrode or welding wire, expressed in pounds per hour. itis based on continuous operation, nat allawing time for stops and starts caused by inserting a new electrode, cleaning slag, termination of the weld or other reasons. The deposition rate will increase as the welding current is increased 9.224 — When using solid ar flux cored wires, deposition rate will increase as the electrical stick-out is increased, and the same amperage is maintained. True deposition rates for each ‘welding filer metal, whether itis a coated electrode or a solid or Mux cored wire, can only be established by an actual test in which the weldment is weighed before welding and then again after welding, atthe end of a measured period of time. The tables in Figures 8-11 contain average values for the deposition rate of various types of welding filler metals. These are based on welding laboratory tests and published dataLESSON IX 9.2.3 Operating Factor - Operating factor is the percentage of a welder's working day that is actually spentwelding. Itis the arctime in hours divided by the total hours worked. A 45% (45) operating factor means that only 45% of the welder's day is actually spent welding. The balance of time is spentinstalling a new electrode or wire, cleaning slag, positioning the weldment, cleaning spatter from the welding gun, etc. 9.231 When using coated electrodes, (SMAW) the operating factor can range from 18%-40% depending upon material handling, fixturing and operator dexterity. the actual operating factor is not known, an average of 30% may be used for cost estimates when weld- ing with the shielded metal arc welding process 9.2.3.2 When welding with solid wires (GMAW) or metal cored welding (MCAvV) using the semi-automatic method, operating factors ranging from 45%-55% are easily attainable. Use 50% for cost estimating purposes. 9.2.3.3 Forwelds produced by flux cored arc welding (FCAW) semi-automatic- ally, the operating factor usually lies between 40%-50%. For cost estimating purposes, use a 45% operating factor. The estimated operating factar for FCAW is about 5% lower than that of GMAW to allow for slag removal time. 9.234 — Insemi-automaticsubmerged arc welding, slag removal and loose flux handling must be considered. A 40% operating factor is typical for this process 9.235 — Automaticwelding using the GMAW, FCAW, and SAW processes, requires that each application be studied individually. Operating factors ranging from 50% to values ap- proaching 100% may be obtained depending on the degree of autamation. 923.6 — The chart in Figure 2 shows average operating factor values for the various welding processes that may be used for cost estimating when the actual operating factor is not known WELDING PROCESS SMAW. cuaw SFCAW. SAW. 40% “Semi-Automatic Only + Metel Cored Wires ere Included APPROXIMATE OPERATING FACTOR: FIGURE 2LESSON IX 924 Deposition Efficiency - Deposition efficiency is the relationship of the weight of the weld metal deposited to the weight of the electrade (or wire) consumed in making a weld. it can be accurately determined only by making a timed test weld, and carefully weighing the ‘weldment and the electrode or wire, before and after welding. The efficiency can then be calculated by the formula: Deposition efficiency = Weight of Weld Metal + Weight of Electrode Used for) Deposition Rate (Ios/hr) = Burn-off Rate (los/hr) 9.2.4.1 The deposition efficiency tells us how many pounds of weld metal can be expected from a given weight of the electrode or welding wire purchased. As an example, 100 pounds of a flux cored electrode with an efficiency of 85%, will produce approximately 85 pounds of ‘weld metal, while 100 pounds of coated electrode with an efficiency of 65%, will produce approximately 65 pounds of weld metal, less the weight ofthe stubs discarded, as described below. 9.2.5 Coated Electrodes - The deposition efficiency of coated electrodes by AWS definition, and in published data, does not consider the loss of the unused electrode stub that is discarded. This is understandable since the stub length can vary with the operator and the application. Long continuous welds are usually conducive to short stubs while on short inter- mittent welds, stub length tends to be longer. Figure 3 illustrates how the stub loss influences the electrode efficiency when using coated electrades. 9.2.5.4 — InFigure 3, a 14° long by 5/32" diameter £7018 electrode at 140 amperes is con- sidered. itis 75% efficient, and a two inch stub loss is assumed. The 75% efficiency applies 1Z LENGTH OF ELECTRODE CONSUMED ————| AMOUNT THET BECOMES WELD METAL EB _— —S sue |x {LENGTH CONSUMED x EFFICIENCY) ise Lost ¢ | siag.srarter > ‘FUMES ‘6 DEFOSITION EFFICIENCY ‘sctual efficiency, inciuding stub oss FIGURE 3 4LESSON IX only to the 12° of the electrode consumed in making the weld, and not to the two inch stub. ‘When the two inch stub loss and the 25% that is lost to slag, spatter and fumes are consid- ered, the efficiency minus stub lossis lowered to 64.3%. This means that for each 100 pounds of electrodes purchased, you can expect an actual deposit of approximately 64.3 pounds of ‘weld metal if all electrodes are used to a two inch stub length. 9.25.2 The formula for the efficiency including stub loss is important, and must always be used when estimating the cost of depositing weld metal by the SMAW method. Figure 4 shows the formula used to establish the efficiency of coated elecirades including stub loss. It is based on the electrode length, and is slightly inaccurate, i.e. itdoes nottake into consider- ation that the electrode weight is not evenly distributed, due to the flux being removed from the electrode holder end. (Indicated by the dotted lines in Figure 3.) Use of the formula will result in a 1.5-2.3% error that will vary with electrode size, coating thickness and stub length. The formula however, is acceptable for estimating purposes, 925.3 Forthe values given in Figure 3 the formula is: EFFICIENCY © = (ELECTRODE LENGTH — STUB LENGTH) X DEPOSITION EFFICIENC MINUS STUB LOSS ELECTRODE LENGTH EFFICIENCY MINUS STUB LOSS. FIGURE 4 Efficiency - Stub Loss = (142)075 44 = 12x75 14 =» Be 14, = 6420 or 64.3% In the above example, the electrode length is known, the stub loss must be estimated, and the efficiency taken from the tables in Figures 8 and 9, Use an average stud lass of three inches for coated electrodes ifthe actual shop practices conceming stub loss are not known. 9.2.5.4 — The following stub loss correction table will assist in your determination of coated electrode efficiencies. Figure 5 lists various efficiencies at a given stub loss.LESSON IX suec. | verosiion z 3 ‘ g encte | eFriciency | stus sTus, sus, STU 60% 50.086 45.0% 40.0% 35.0% 5% 54.2% 48.7% 43.3% 37.9% 12 70% 58.2% 52.5% 40.0% 40.8% 75% 62.5% 56.2% 50.0% 43.7% 036 enn 0.0 3% an 66 STUB LOSS CORRECTION 20% 51.4% 47.1% 428% 28.5% TABLE FOR GGATED 5% 55.756 51.1% 46.4% 41.356 ELECTRODES 14 70% 0.0% 55.0% 50.0% 45.0% EFFICIENCY INCLUDING a Bas =e 280- 2625 = 062 POWER “"To00 x DEPOSITION RATE 1000 x 6.38 5,360 TOTAL COST PER LB OF 5 $ 19.60 GOFAL COST PER LB, OF SUMOF 1 THROUGH SABovE _$ 19.60 _ COST PER FOOT OF DEPOSITED WELD METAL COST PER POUND POUNDS PER OFDEPOSTED X FOOT OF. = 19.60% B14 = $15.95 WELD METAL WELD JOINT COST OF WELD METAL - TOTAL JOB TOTAL FEET y COSTPER - Spade 125298) $20 2822 OF WELD FOOT FIGURE 12LESSONIX Line § - Cost of Power - $ .045/KWh (given). Volts & Amperes - 25V and 250A (given). Constant- The 1,000 already entered, is a constant necessary to convertto watthours. Deposition Rate - 5.36 Ibsihr as used in Line 4 The cost of electrical power to deposit one pound of weld metal can now be calculated as $.052. Line 6 - Total Lines 1, 2, and 5 to find the tatal cost of depasiting one pound weld metal. The total of $19.60. 9.4.2 Calculating The Cost Per Foot of Deposited Weld Metal Calculating the weight of weld metal requires that we consider the following items. a. Area of the cross-section of the weld, b. Length of the weld. © Volume of the weld in cubic inches. d. Weight of the weld metal per cubicinch 9.4.21 — Inthe fillet weld show in Figure 13, we know that the area of the cross-section (the triangle) is equal to one-haifthe base times the height, the volume of the weldis equal to the area times the length, and the weight of the weld then, is the volume times the weight of the material (steel) per cubic inch 94.22 We can then write the formula Weight of Weld Metal = % x Base x Height x Length x Weight of Material Substituting the values from Figure 13, we have: WHF = 5 %.5% 5 x12 x 283= .4245 Ibs 9.4.2.3 Weights may vary depending on the density of the particular material you are at- tempting to calculate. The chart in Figure 14 will eliminate the need for these calculatians for steel fillet and butt joints, since it lists the weight per foot directly. 9.424 — Estimating the weight per foot of a weld using the chart, requires thatyou make a drawing of the weld joint to exact scale, and dimension the leg lengths, roat ap, thickness, angles and ather pertinent measurements as shown in Figure 15. Divide the cross-section of the weld into right triangles and rectangles as shown. Sketch in the reinforcement, i.e., theLESSON IX ry HEIGHT ee eral seid Sues ‘Weight of Wel (2 (W2)x 12x 12x 283 ae eng CALCULATING THE WEIGHT PER FOOT OF A FILLET WELD FIGURE 12 domed portion above or below the surface of the plate, where required. The reinforcement should extend slightly beyond the edges of the joint. Measure the lenath and height of the reinforcement and note them on your drawing. The reinforcement is only an approximation because the contour cannot be exactly controlled in welding. Refer to the weight tables in Figure 14 for the weights per foot of each of the component parts of the weld, as sketched. The sum ofthe weights of all the components is the total weight of the weld, per foots shown in Figure 154, Line 7 - The total cost per pound as determined in Line 6 is entered, and mult- plied by the weight per foot as determined in Figure 14. 9.4.3 Calculating the Cost of Weld Metal - Total Job Line 8- The cost af the weld forthe total jab is determined by multiplying the total feet of weld (given) by the cost per footas determined in Line 7 9.5 COST CALCULATIONS - EXAMPLE 2 Calculate the total cost of depositing 1280 ft of weld metal using the CO2 shielded, flux cored welding process in the double V-groove joint shawn in Figure 14 using the following data Electrode - 3/32", E7071 @ 34 volts, 450 amps. Labor and Overhead - $30.00/hr. Deposition Rate- 1S losihr, From Table in Figure 10. Operating Factor - 45% (45). Average from Figure 2. RenaLESSON IX WEIGHT FER FOOT OF WELD METAL FOR FILLET WELDS AND ELEMENTS OF CONNON BUTT JOINTS (lts/tt) ‘STEEL EQUAL LEG FILLETS: (USE 45*COLUMN) SINGLE SINGLE BEVEL V-GROOVE a 4 LON ; WH at t sae ae ovale sicLe ere sacerRaR i RARE - Ei E : Inches the" ta" se tier ast torte zene ane get ae eaten te 48 007 «05308106 «159-242 002.005 OUT Ot 015027 ane 040 080 119 189 239 212 005 OM 08 025 025 060 027 SNe co 133 189 266 390 621 015 028 04a 069 096 166 Odd sea. 38 080189239 3181478637 «021 082 064 «099-138-239 053-106. Wie 081 188 27a la7l 887 743 028 «OST 087 «128188325 082124 10 212 318 425 637 849 037 O75 «114 «176245428 O71 141 212 aie 115 (239 581478718955 047 «085144223311 1451 080158 239 pe 193 Des 308 eat 798 1861 O58 7 178 275 [sea eed ope 177 Des age 416 148 292 498 584 876 1487 070 142 215 332 484 204 087 195 282 388 aa 189 BIB 478 82T «995 1274 ORs 169 258-308 52 OBE 106 «212 21RD 4218 172 285 S17 90 1025 1280 098 198 201 464 648 (1.121.118 220 248.480 7186 Br ser 743 1.114 1486 114 (230 349 538 751 11300 124 “bag 371495 186 199 398 S87 (Tee 1194 1592 131 263 400 618 863 1493-133 206 398 630 1 212 425 837 849 1.274 1.698 149 200 450 702.981 1.698.141 283 424.988 299° 478 FAG 955 1.493 1910 188 879 S77 89D 1.241 2149.15 ate 47787 414 (265 g31 798 4.081 1.592 2123 232 488 712 1.090 1.532 2653.17 354 821 707 4a 392 gga 870 1167 1.751 2325 381 (ser Bo! 1.330 1353 3210 195 az9 Bea 777 412 318 (es7 (885 1274 1910 2e4y B3¢ eve 1023 1582 2200 3821 212 (424 cay 848 45 245 680 1.035 4.80 2089 2765 393 782 4201 1.867 2589 4.484.290 480 660 920 43/4 371 743 1.114 1.496 2.229 2872 465 918 1.393 2.154 3002 5200 248 495 743 900 360 796 1.194 1.692 2383 2184 523 1053 1598 2472 3447 5970 200 621 786 1.001 2 425 649 1274 1693 2647 3390 554 1197 1820 2812 3921 6782 283 see B49 1.182 21s 478 955 1.493 1.910 2965 2821 752 1516 2209 3581 4962 8.508.218 837 855 1279 520 1.081 1.692 2123 3194 4245 928 1871 Dead 4.396 6.127 10.619254 707 1.081 1.415 24 (sB4 1487 1.751 2335 2502 4869 1122 2264 3441 5.219 7.414 12841289 778 1467 1556 3 636 1274 1910 2547 3821 5096 1237 2e95 4095 6.220 3823 16282424 849 1273 1€58 (© COPYRIGMT 2000 THE ESAE GROUP ONC. FIGURE 44.LESSON IX ae Ibs a7ex4= 704 avix2= 143 TOTAL WEIGHTIFT. “Ba6 Ibs TOTAL WEIGHTIFT, “B14 Ibs ESTIMATING WELD METAL WEIGHT FIGURE 18 Electrode Cost- $.80/lb (from supplier), Deposition Efficiency - 86% (.86) From Table in Figure 10. Gas Flow Rate - 45 cubic feet per hour. From Figure 7. epxyaw Gas Cost- $.03/cubic foot (from supplier). 9. Cost of Power - §.045/KWh. 10. WEFT of Weld - From Figure 158 = 846 Insift These values are shown inserted into the formulas on the Weld Metal Cast Worksheet in Figure 16. 9.6 COMPARING WELD METAL COSTS Itis interesting to note that the amount of weld metal deposited in Example 1 and Example 2 is almast the same, while the total cost of depasiting the weld metal is three times higher in Example 1 as shown below. This is because the flux cored process has a higher deposition rate, efficiency and operating factor and also allows a tighter joint due to the deep penetrating characteristics ofthe process. Example 1-1,280ftx.814 lbsift = 1,047.9 Ibs at $13,939 Example 2- 1,280 f1x.846 Ibsift 1,082.9 Ibs at $ 4,352 9.6.0.1 When comparing welding processes, all efforts should be made to assure that you use the proper welding current for the electrade or wire in the position in which the weld must be made. Asan example, consider depositing a given size fillet weld in the vertical-up posi-LESSON IX EXAMPLE 2 WELD METAL COST WORKSHEET COST PER POUND OF DEPOSITED WELD METAL LABOR a LABOR OVERHEAD COSTIUR = ae 444 OVERHEAD “DEPOSITION OPERATING 15x 45 a RATE (LES/HR) x FACTOR 3 ~ i 20 ELECTRODE ELECTRODE COST/LB_ “ oe nee DEPOSITION EFFICIENCY 56 3 GAS FLOW RATE GAS (CUFTHR) x Gascosricurr = _45x03__ deol DEPOSITION RATE (LBS/HR) 16 15 * costa x44 NA riux -«-FLUX.COSTULB x 4g 2 pO pe ~~ DEPOSITION EFFICIENCY 5. cOsTaWh x VOLTS x amps _ B45 X34 450 - 62176 _ 0a POWER “7000 DEPOSITION RATE, 1000 x 15 15,000 e TOTAL GOST PER LB. OF oH SA 551 6 DEPOSITED WELD METAL SUMOF 1 THROUGH SABOVE _S5S1 _ COST PER FOOT OF DEPOSITED WELD METAL 7 cost PER POUND POUNDS PER OFDEPOSITED =X © FOOTOF = pee as 08 WELD METAL WELD JOINT COST OF WELD METAL - TOTAL JOB 8 TOTALFEET x COST FER - 4,280x 4.86 = 85/965 OF WELD Foot FIGURE 16LESSONIX fion by the GMAW process and FCAW process semi-automatically. In both processes the welding current and voltage must be lowered to weld out-of-position, and in GMAW, the short circuiting arc transfer must be used. Example 3 compares the weld metal cost per pound deposited by these processes, using the proper current and voltage for depositing a "fillet weld on 1" plate, vertically up. Note: The cost of electrical power is comparable in all processes and therefore, can be eliminated as a factor. 9.6.4 Example 3 ECAW GMAW Electrode Type - 048" dia. E7114 O48" dia. ERTOS-3 Labor & Overhead - $30.00/mr $30.00mnr Welding Current - 180 amperes 125 amperes Deposition Rate - 4.9 Ibsinr (Fig. 9) 2.8 Ibsihr (Fig. 10) Operating Factor- 45% (Fig. 2) 50% (Fig. 2) Electrode Cost- $1.44/Ib $.66ilb Deposition Efficiency - 85% (Fig. 9) 96% (Fig. 6) Gas Flow Rate - 35 chh (Fig. 7) 35 ofh (Fig. 7) Gas Cost Per Cu. Ft.- $.03 CO, $.11 75% Ar/25% CO, This data is tabulated in the chartin Figure 17. 9.6.1.1 AS youcan see, the cost of depasiting the weld metal is about 33% less using the Flux Cored Arc Welding process. Since there is na slag to help hold the vertical weld puddle in the GMAW process, the welding current with solid wire must be lowered considerably. This, ‘of course, lowers the deposition rate, and since labor and overhead is the largest factor in- volved, it substantially raises depasition costs. In the flat or horizontal position, where the welding current on the solid wire would be much higher, the cost difference would be consider- ably less pronouncedLESSON IX NAME INFO lation (2) Present Meth Flux Con EVIT-4 048 $30.00 ng x 0. 320.00. 49 X OMG 9.7_ OTHER USEFUL FORMULAS The information discussed below will assist you in making other useful calculations: TOTAL POUNDS OF ELECTRODES REQUIRED (REF. EXAMPLE 1) Total Pounds = —WUFLof Weld x No. of Ft of Weld Deposition Efficiency 814 x 1,280 ‘Substituting the values from Example 1: =—————__ = 1.631 Ibs 630 WELDING TIME REQUIRED (REF. EXAMPLE 1) WUFt of Weld x Ft of Weld Welding Time = § ———" —"$*—S —__ Deposition Rate x Operating Factor Substituting the values in Example 1: 8144x1280. . 1042 _ G45 tis 5.36 x 30 1.608LESSON IX 9.8 AMORTIZATION OF EQUIPMENT COSTS Calculations show that you can save $7.00 per pound of deposited weld metal by switching from £7018 electrodes and the SAW process to an ER70S0-3 solid wire using the GMAW process. However, the cost of the necessary equipment (power source, wire feeder and gun) is $2,800. How long willt take to amortize or regain the cast of the equipment knowing that the deposition rate of the ER70S-3 is 7.4 lbs/hr and the operating factor of the GMAW process is $0%2 The formula is: Equipment Cost a A oe SSavingalp 7 (epesiion Ratex Operating Factor) = Man Hrs Substituting the values in the formula: 400 * 3. H we divide 108 into eight hour days (108 = 8 = 12.5) the deposited weld metal savings of one man working an eight hour day for 13-1/2 days will pay for the cost of the equipment. ‘zo THE EBB GROUE ‘NC!