Lesson 9

Lesson 9 - Estimating & Comparing Weld Metal Costs
Current
Lesson 1
Chapter
The Basics of Arc
Table of
Welding
Contents
Lesson 2
Common Electric
Arc Welding
Processes
BASIC Go To Test
Lesson 3
Covered Electrodes
for Welding
WELDING FILLER METAL Print
Mild Steels
TECHNOLOGY
Lesson 4 Glossary
Covered Electrodes
for Welding Low A Correspondence Course
Alloy Steels
Lesson 5
Welding Filler Metals
for Stainless Steels
LESSON IX Turn Pages
Lesson 6
Request
Carbon & Low Alloy
Steel Filler Metals - ESTIMATING Certificate
After
GMAW,GTAW,SAW
AND COMPARING Completion
Lesson 7 Search
Flux Cored Arc WELD METAL COSTS Chapter
Electrodes Carbon (Faster
Low Alloy Steels Download)
Search
Document
Lesson 8 (Slower
Hardsurfacing Download)
Electrodes
ESAB ESAB Welding &
Cutting Products
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Reliability of Welding
Filler Metals
©COPYRIGHT 2000 THE ESAB GROUP, INC.
http://www.esabna.com/EUWeb/AWTC/Lesson9_1.htm8/18/2004 4:33:55 AM
Current
Lesson 1
Chapter
The Basics of Arc
Table of
Welding
TABLE OF CONTENTS Contents
LESSON IX
Lesson 2
Common Electric ESTIMATING AND COMPARING WELD
Arc Welding METAL COSTS
Processes
Go To Test
Lesson 3
Section Nr. Section Title Page
Covered Electrodes
9.1 Introduction .................................................................................................. 1 Print
for Welding
Mild Steels
9.2 Factors For Cost Formulas ...................................................................... 2
Lesson 4 9.2.1 Labor & Overhead ......................................................................................... 2

Glossary
Covered Electrodes 9.2.2 Deposition Rate ............................................................................................. 2
for Welding Low 9.2.3 Operating Factor ............................................................................................ 3
Alloy Steels 9.2.4 Deposition Efficiency .................................................................................... 4
9.2.5 Deposition Efficiency of Coated Electrodes .............................................. 4
Lesson 5 9.2.6 Efficiency of Flux Cored Wires ..................................................................... 6
9.2.7 Efficiency of Solid Wires for GMAW ............................................................ 6
9.2.8 Efficiency of Solid Wires for SAW ............................................................... 7
9.2.9 Cost of Electrodes, Wires, Gases and Flux ................................................ 7 Turn Pages
Lesson 6 9.2.10 Cost of Power ................................................................................................ 7
Request
Carbon & Low Alloy
Certificate
Steel Filler Metals - 9.3 Deposition Data Tables ............................................................................. 8
After
GMAW,GTAW,SAW
Completion
9.4 Cost Calculations ....................................................................................... 12
Lesson 7 9.4.1 Calculating the Cost Per Pound of Deposited Weld Metal ....................... 12 Search
Flux Cored Arc Chapter
9.4.2 Calculating the Cost Per Foot Of Deposited Weld Metal ......................... 14
Low Alloy Steels 9.5
Download)
Cost Calculations - Example 2 ................................................................ 15
Search
9.6 Comparing Weld Metal Costs .................................................................. 17 Document
Lesson 8 (Slower
9.6.1 Example 3 ....................................................................................................... 19
Electrodes 20
9.7 Other Useful Formulas ..............................................................................
9.8 Amortization of Equipment Costs .......................................................... 21

Lesson 9
Estimating &
Appendix A Lesson IX Test Questions ......................................................................... 22
Comparing Weld
Metal Costs Appendix B Problem 1 Worksheet ................................................................................ 26
Appendix C Problem 2 Worksheet ................................................................................ 27

Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
ESTIMATING AND COMPARING WELD METAL COSTS Contents
Lesson 2
Common Electric
Arc Welding
Processes
9.1 INTRODUCTION
Go To Test
Estimating the costs of depositing weld metal can be a difficult task because of the many
Lesson 3
Covered Electrodes 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, Print
for Welding
Mild Steels and type 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
Lesson 4 most expediently must be carefully considered. Labor and overhead account for approxi- Glossary
Covered Electrodes
mately 85% of the total welding cost.
for Welding Low
Alloy Steels 9.1.0.1 Welding costs may be divided into two categories; the “fixed” costs involved regard-
less of the filler metal or welding process selected, and those related to a specific welding
Lesson 5 process. Fixed costs entail material handling, joint preparation, fixturing, 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 left to the manufacturer since they will depend upon his capabilities Turn Pages
Lesson 6 and equipment. The cost of actually depositing the weld metal however, will vary considerably Request
Carbon & Low Alloy
with the filler metal and welding process selected. This cost element is influenced by the Certificate
Steel Filler Metals -
user’s labor and overhead rates, deposition rate and efficiency of the filler metal, operating After
GMAW,GTAW,SAW
factor, and cost of materials and power. Completion
Lesson 7 Search
9.1.0.2 This lesson will cover cost estimating for steel weldments produced by the four most Chapter
Flux Cored Arc
Electrodes Carbon common arc welding processes in use today: shielded metal-arc welding, gas metal-arc (Faster
Low Alloy Steels welding, flux cored arc welding and submerged arc welding. Gas tungsten arc welding will not Download)
be considered here because the variables, such as deposition rate and efficiency, are depen- Search
dent on operator technique, stub use, etc. The GTAW process is a relatively costly method of Document
Lesson 8 (Slower
Hardsurfacing depositing weld metal, and is usually chosen for weld quality or material thickness and compo-
Download)
Electrodes sition limitations, rather than economy.
9.1.0.3 Large firms will frequently conduct their own deposition tests and time studies to
Lesson 9
determine welding costs, but many smaller shops do not know the actual cost of depositing
Estimating &
weld metal.
Comparing Weld
Metal Costs
9.1.0.4 In estimating welding costs, all attempts should be made to work with accurate data,
which in some cases is difficult to secure. For this reason, this lesson contains charts, graphs
Lesson 10
Filler Metals
© COPYRIGHT 2000 THE ESAB GROUP, INC.
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
and tables that provide average values that you may use. Electrode manufacturers will usually Contents
supply the deposition data you need through their Technical Services Department, if it is not
Lesson 2 already published in their literature.
Common Electric
Arc Welding
Processes
9.2 FACTORS FOR COST FORMULAS Go To Test

Lesson 3
Covered Electrodes
9.2.1 Labor and Overhead - Labor and overhead may be considered jointly in your Print
for Welding
Mild Steels 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-
Lesson 4 facturing plants normally have established labor and overhead rates for each department.
Glossary
Covered Electrodes Labor and overhead rates can vary greatly from plant to plant, and also with location. Figure 1
for Welding Low shows how labor and overhead may vary and suggests an average value to use in your calcu-
Alloy Steels
lations when the actual value is unknown.
Lesson 5
Welding Filler Metals HOURLY WELDING LABOR & OVERHEAD RATES
for Stainless Steels Small Shops $10.00 to $25.00/hr.

Large Shops $25.00 to $50.00/hr
Turn Pages
Average $30.00/hr.
Lesson 6
APPROXIMATE LABOR AND OVERHEAD RATES Request
Carbon & Low Alloy
Certificate
Steel Filler Metals - FIGURE 1
After
GMAW,GTAW,SAW
Completion
9.2.2 Deposition Rate - The deposition rate is the rate that weld metal can be deposited Search
Lesson 7
by a given electrode or welding wire, expressed in pounds per hour. It is based on continuous Chapter
Flux Cored Arc
Electrodes Carbon operation, not allowing time for stops and starts caused by inserting a new electrode, cleaning (Faster
Low Alloy Steels slag, termination of the weld or other reasons. The deposition rate will increase as the welding Download)
current is increased. Search

Document
Lesson 8 (Slower
9.2.2.1 When using solid or flux cored wires, deposition rate will increase as the electrical
Electrodes stick-out is increased, and the same amperage is maintained. True deposition rates for each
welding filler metal, whether it is a coated electrode or a solid or flux cored wire, can only be
established by an actual test in which the weldment is weighed before welding and then again
Lesson 9
after welding, at the end of a measured period of time. The tables in Figures 8-11 contain
Estimating &
Comparing Weld average values for the deposition rate of various types of welding filler metals. These are
Metal Costs based on welding laboratory tests and published data.
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding 9.2.3 Operating Factor - Operating factor is the percentage of a welder’s working day Contents
that is actually spent welding. It is the arc time in hours divided by the total hours worked. A
Lesson 2 45% (.45) operating factor means that only 45% of the welder’s day is actually spent welding.
Common Electric The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the
Arc Welding
weldment, cleaning spatter from the welding gun, etc.
Processes
9.2.3.1 When using coated electrodes, (SMAW) the operating factor can range from Go To Test
Lesson 3
15%-40% depending upon material handling, fixturing and operator dexterity. If the actual
Covered Electrodes
operating factor is not known, an average of 30% may be used for cost estimates when weld- Print
for Welding
Mild Steels ing with the shielded metal arc welding process.
9.2.3.2 When welding with solid wires (GMAW) or metal cored welding (MCAW) using the
Lesson 4 Glossary
Covered Electrodes semi-automatic method, operating factors ranging from 45%-55% are easily attainable. Use
for Welding Low 50% for cost estimating purposes.
Alloy Steels
9.2.3.3 For welds produced by flux cored arc welding (FCAW) semi-automatically, the
operating factor usually lies between 40%-50%. For cost estimating purposes, use a 45%
Lesson 5
Welding Filler Metals operating factor. The estimated operating factor for FCAW is about 5% lower than that of
for Stainless Steels GMAW to allow for slag removal time.
Turn Pages
9.2.3.4 In semi-automatic submerged arc welding, slag removal and loose flux handling
Lesson 6 must be considered. A 40% operating factor is typical for this process. Request
Carbon & Low Alloy
Certificate
Steel Filler Metals - 9.2.3.5 Automatic welding using the GMAW, FCAW, and SAW processes, requires that After
GMAW,GTAW,SAW
each application be studied individually. Operating factors ranging from 50% to values ap- Completion
proaching 100% may be obtained depending on the degree of automation. Search
Lesson 7
9.2.3.6 The chart in Figure 2 shows average operating factor values for the various welding (Faster
Electrodes Carbon
processes that may be used for cost estimating when the actual operating factor is not known. Download)
Low Alloy Steels
Search
Document
Lesson 8 (Slower
Electrodes WELDING PROCESS
+ * GMAW
SMAW *FCAW *SAW
Lesson 9 30% 50% 45% 40%
Estimating &
Comparing Weld *Semi-Automatic Only
+ Metal Cored Wires are Included
Metal Costs APPROXIMATE OPERATING FACTOR
FIGURE 2
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding 9.2.4 Deposition Efficiency - Deposition efficiency is the relationship of the weight of Contents
the weld metal deposited to the weight of the electrode (or wire) consumed in making a weld.
Lesson 2 It can be accurately determined only by making a timed test weld, and carefully weighing the
Common Electric weldment and the electrode or wire, before and after welding. The efficiency can then be
Arc Welding
calculated by the formula:
Processes
Deposition efficiency = Weight of Weld Metal ÷ Weight of Electrode Used Go To Test
Lesson 3
(or)
Covered Electrodes
Deposition Rate (lbs/hr) ÷ Burn-off Rate (lbs/hr) Print
for Welding
Mild Steels
9.2.4.1 The deposition efficiency tells us how many pounds of weld metal can be expected
Lesson 4 Glossary
Covered Electrodes from a given weight of the electrode or welding wire purchased. As an example, 100 pounds
for Welding Low of a flux cored electrode with an efficiency of 85%, will produce approximately 85 pounds of
Alloy Steels weld metal, while 100 pounds of coated electrode with an efficiency of 65%, will produce
approximately 65 pounds of weld metal, less the weight of the stubs discarded, as described
Lesson 5 below.
for Stainless Steels 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
Turn Pages
is discarded. This is understandable since the stub length can vary with the operator and the
Lesson 6
application. Long continuous welds are usually conducive to short stubs while on short inter- Request
Carbon & Low Alloy
Certificate
Steel Filler Metals - mittent welds, stub length tends to be longer. Figure 3 illustrates how the stub loss influences
After
GMAW,GTAW,SAW the electrode efficiency when using coated electrodes.
Completion
Lesson 7 9.2.5.1 In Figure 3, a 14” long by 5/32” diameter E7018 electrode at 140 amperes is con- Search
sidered. It is 75% efficient, and a two inch stub loss is assumed. The 75% efficiency applies
Search
12" LENGTH OF ELECTRODE CONSUMED Document
Lesson 8 (Slower
2"
Hardsurfacing AMOUNT THAT BECOMES WELD METAL
STUB Download)
(LENGTH CONSUMED X EFFICIENCY)
Electrodes LENGTH
Lesson 9 LOST TO
Estimating & 9" SLAG,SPATTER
& FUMES
Comparing Weld
14"
Metal Costs
DEPOSITION EFFICIENCY = 75%
actual efficiency, including stub loss = 9 ÷ 14 = 64.3%
Lesson 10 FIGURE 3
Reliability of Welding © COPYRIGHT 2000 THE ESAB GROUP, INC.
Filler Metals -4-
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
only to the 12” of the electrode consumed in making the weld, and not to the two inch stub. Contents
When the two inch stub loss and the 25% that is lost to slag, spatter and fumes are consid-
Lesson 2 ered, the efficiency minus stub loss is lowered to 64.3%. This means that for each 100 pounds
Common Electric of electrodes purchased, you can expect an actual deposit of approximately 64.3 pounds of
Arc Welding
weld metal if all electrodes are used to a two inch stub length.
Processes
9.2.5.2 The formula for the efficiency including stub loss is important, and must always be Go To Test
Lesson 3
used when estimating the cost of depositing weld metal by the SMAW method. Figure 4
Covered Electrodes
shows the formula used to establish the efficiency of coated electrodes including stub loss. It Print
for Welding
Mild Steels is based on the electrode length, and is slightly inaccurate, i.e. it does not take into consider-
ation that the electrode weight is not evenly distributed, due to the flux being removed from the
Lesson 4 electrode holder end. (Indicated by the dotted lines in Figure 3.) Use of the formula will result
Glossary
Covered Electrodes in a 1.5-2.3% error that will vary with electrode size, coating thickness and stub length. The
for Welding Low formula however, is acceptable for estimating purposes.
Alloy Steels
9.2.5.3 For the values given in Figure 3 the formula is:
Lesson 5
EFFICIENCY = (ELECTRODE LENGTH — STUB LENGTH) X DEPOSITION EFFICIENCY
for Stainless Steels MINUS STUB LOSS ELECTRODE LENGTH
Turn Pages
EFFICIENCY MINUS STUB LOSS
Lesson 6
FIGURE 4 Request
Carbon & Low Alloy
Certificate
Efficiency - Stub Loss = (14-2) x .75 After
GMAW,GTAW,SAW
14 Completion
Lesson 7 12 x .75 Search

=
14
= 9 Download)
Low Alloy Steels
14 Search
= .6429 or 64.3% Document
Lesson 8 (Slower
In the above example, the electrode length is known, the stub loss must be estimated, and the
Electrodes
efficiency taken from the tables in Figures 8 and 9. Use an average stub loss of three inches
for coated electrodes if the actual shop practices concerning stub loss are not known.
Lesson 9
Estimating & 9.2.5.4 The following stub loss correction table will assist in your determination of coated
Comparing Weld electrode efficiencies. Figure 5 lists various efficiencies at a given stub loss.
Metal Costs
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
ELEC. DEPOSITION 2" 3" 4" 5" Contents
LENGTH EFFICIENCY STUB STUB STUB STUB
60% 50.0% 45.0% 40.0% 35.0%

Lesson 2
65% 54.2% 48.7% 43.3% 37.9%
Common Electric
12" 70% 58.3% 52.5% 46.6% 40.8%
Arc Welding
75% 62.5% 56.2% 50.0% 43.7%
Processes
80% 66.6% 60.0% 53.3% 46.6%
STUB LOSS CORRECTION
60% 51.4% 47.1% 42.8% 38.5% Go To Test
Lesson 3 TABLE FOR COATED
65% 55.7% 51.1% 46.4% 41.8%
ELECTRODES
Covered Electrodes 14" 70% 60.0% 55.0% 50.0% 45.0%
EFFICIENCY INCLUDING Print
for Welding 75% 64.3% 58.9% 53.6% 48.2%
Mild Steels STUB LOSS
80% 68.5% 62.8% 57.1% 51.4%
FIGURE 5 60% 53.3% 50.0% 46.6% 43.3%
Lesson 4 65% 57.7% 54.2% 50.5% 46.9%

Glossary
Covered Electrodes 18" 70% 62.2% 58.3% 54.4% 50.5%
for Welding Low 75% 66.6% 62.5% 58.3% 54.2%

80% 71.1% 66.6% 62.2% 57.7%
Alloy Steels
9.2.6 Efficiency of Flux Cored Wires - Flux cored wires have a lower flux-to-metal ratio
Lesson 5
than coated electrodes, and thereby, a higher deposition efficiency. Stub loss need not be
considered since the wire is continuous. The gas shielded wires of the E70T-1 and E70T-2
types have efficiencies of 83%-88%. The gas shielded basic slag type (E70T-5) is 85%-90%
efficient with CO2 as the shielding gas, and the efficiency can reach 92% when a 75% argon, Turn Pages
Lesson 6 25% CO2 gas mixture is used. Use the efficiency figures in Figure 9 for your calculations if the Request
Carbon & Low Alloy
actual values are not known. Certificate
After
GMAW,GTAW,SAW
9.2.6.1 The efficiency of the self-shielded types of flux cored wires has more variation Completion
because of the large variety of available types that have been designed for specific applica- Search
Lesson 7
tions. The high deposition general purpose type, such as E70T-4, is 81%-86%, depending on Chapter
Flux Cored Arc
Electrodes Carbon wire size and electrical stick-out. The chart in Figure 9 shows the optimum conditions for each (Faster
Low Alloy Steels wire size and may be used in your calculations. Download)
Search
9.2.7 Efficiency of Solid Wires for GMAW - The efficiency of solid wires in GMAW is Document
Lesson 8 (Slower
very high and will vary with the shielding gas or gas mixture used. Using CO2 will produce the
Electrodes most spatter and the average efficiency will be about 93%. Using a 75% argon-25% CO2 gas
mixture will result in somewhat less spatter, and an efficiency of approximately 96% can be
expected. A 98% argon-2% oxygen mixture will produce even less spatter, and the average
Lesson 9
efficiency will be about 98%. Stub loss need not be considered since the wire is continuous.
Estimating &
Comparing Weld Figure 6 shows the average efficiencies you may use in your calculations if the actual effi-
Metal Costs ciency is not known.
Lesson 10
Filler Metals
Current
Lesson 1
.045" - 1/16" LESSON IX Chapter
The Basics of Arc
Table of
GMAW Welding 9.2.8 Efficiency of Solid Wires for SAW - In submerged arc welding there is no spatter Contents
loss and an efficiency of 99% may be assumed. The only loss during welding is the short
Lesson 2 piece the operator must clip off the end of the wire to remove the fused flux that forms at the
Common Electric termination of each weld. This is done to assure a good start on the succeeding weld.
Arc Welding
Processes
Go To Test
Lesson 3 Shielding Efficiency Average
Covered Electrodes Gas Range Efficiency
Print
for Welding Pure CO2 88 - 95% 93%
Mild Steels
94 - 98% 96%
Lesson 4 98% Ar - 2% O2 97 - 98.5% 98% Glossary

Covered Electrodes
DEPOSITION EFFICIENCIES - GAS METAL ARC WELDING
for Welding Low CARBON AND LOW ALLOY STEELS
Alloy Steels FIGURE 6
Lesson 5 9.2.9 Cost of Electrodes, Wires, Gases and Flux - You must secure the current cost
Welding Filler Metals per pound of the electrode or welding wire, plus the cost of the shielding gas or flux if appli-
for Stainless Steels cable, from the supplier. The shielding gas flow rate varies slightly with the type of gas used.
The flow rates in Figure 7 are average values whether the shielding gas is an argon mixture or Turn Pages
Lesson 6 pure CO2. Use these in your calculations if the actual flow rate is not available.
Request
Carbon & Low Alloy
In the submerged arc process (SAW) the ratio of flux to wire consumed in the weld is approxi- Certificate
After
GMAW,GTAW,SAW mately 1 to 1 by weight. When the losses due to flux handling and flux recovery systems are
Completion
considered, the average ratio of flux to wire is approximately 1.4 pounds of flux for each pound
Lesson 7 Search
of wire consumed. If the actual flux-to-wire ratio is unknown, use the 1.4 for cost estimating.
FCAW/MCAW Search
Wire Diameter .035" .045" 1/16" 5/64" - 1/8" Document
Lesson 8 (Slower
Hardsurfacing CFH 30 35 35 40 45
Download)
Electrodes APPROXIMATE SHIELDING GAS FLOW RATE - CUBIC FEET PER HOUR
FIGURE 7
Lesson 9
Estimating & 9.2.10 Cost of Power - Cost of electrical power is a very small part of the cost of deposit-
Comparing Weld
ing weld metal and in most cases is less than 1% of the total. It will be necessary for you to
Metal Costs
know the power cost expressed in dollars per kilowatt- hour ($/kWh) if required for a total cost
estimate.
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
9.3 DEPOSITION DATA CHARTS
Lesson 2
Common Electric 9.3.1 SHIELDED METAL ARC WELDING - Coated Electrodes.
Arc Welding
Processes
Go To Test
E6010 6013
Lesson 3
ELECTRODE DEPOSITION EFFICIENCY ELECTRODE DEPOSITION EFFICIENCY
Covered Electrodes DIAMETER AMPS RATE lbs/hr % DIAMETER AMPS RATE lbs/hr % Print
for Welding 3/32 75 1.5 72.0% 3/32 85 1.6 73.0%
Mild Steels 1/8 100 2.1 76.3% 1/8 125 2.1 73.0%
130 2.3 68.8% 5/32 140 2.6 75.6%
Lesson 4 5/32 140 2.8 73.6% 160 3 74.1% Glossary
Covered Electrodes 170 2.9 64.1% 180 3.5 71.2%
for Welding Low 3/16 160 3.3 74.9% 3/16 180 3.2 73.9%
190 3.5 69.7% 200 3.8 71.1%
Alloy Steels
7/32 190 4.5 76.9% 220 4.1 72.9%
230 5.1 73.1% 7/32 250 5.3 71.3%
Lesson 5 270 5.7 73.0%
Welding Filler Metals 290 6.1 72.7%
for Stainless Steels E6011
ELECTRODE DEPOSITION EFFICIENCY
DIAMETER AMPS RATE lbs/hr % Turn Pages
E7014
Lesson 6 3/32 75 1.3 61.0% ELECTRODE DEPOSITION EFFICIENCY
Request
Carbon & Low Alloy 1/8 120 2.3 70.7% DIAMETER AMPS RATE lbs/hr %
Certificate
Steel Filler Metals - 5/32 150 3.7 77.0% 1/8 120 2.4 63.9%
3/16 180 4.1 73.4% After
GMAW,GTAW,SAW 150 3.1 61.1%
7/32 210 5 74.2% Completion
5/32 160 3 71.9%
1/4 250 5.6 71.9% 200 3.7 67.0% Search
Lesson 7
Flux Cored Arc 3/16 230 4.5 70.9% Chapter
270 5.5 73.2% (Faster
Electrodes Carbon E6012
7/32 290 5.8 67.2% Download)
Low Alloy Steels ELECTRODE DEPOSITION EFFICIENCY
330 7.1 70.3%
DIAMETER AMPS RATE lbs/hr %
1/4 350 7.1 68.7% Search
1/8 130 2.9 81.8% 400 8.7 69.9% Document
Lesson 8 5/32 165 3.2 78.8% (Slower
Hardsurfacing 200 3.4 69.0% Download)
Electrodes 3/16 220 4 77.0%
250 4.2 74.5%
7/32 320 5.6 69.8%
Lesson 9
Estimating & DEPOSITION DATA - SMAW - COATED ELECTRODES
Comparing Weld FIGURE 8

Metal Costs
NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
Lesson 2
Common Electric
Arc Welding
Processes
E7016 Go To Test
Lesson 3 ELECTRODE DEPOSITION EFFICIENCY
Covered Electrodes DIAMETER AMPS RATE lbs/hr %
Print
for Welding 1/8 100 1.7 63.9%
LOW ALLOY, IRON POWDER ELECTRODES
Mild Steels 130 2.3 65.8%
TYPES E7018, E8018, E9018, E10018, E11018,
5/32 140 3.0 70.5%
160 3.2 69.1% AND E12018
Lesson 4 ELECTRODE DEPOSITION EFFICIENCY Glossary
190 3.6 66.0%
Covered Electrodes DIAMETER AMPS RATE lbs/hr %
3/16 175 3.8 71.0%
for Welding Low 200 4.2 71.0% 3/32 70 1.37 70.5%
Alloy Steels 225 4.4 70.0% 90 1.65 66.3%
250 4.8 65.8% 110 1.73 64.4%
1/4 250 5.9 74.5% 1/8 120 2.58 71.6%
Lesson 5
275 6.4 74.1% 140 2.74 70.9%
300 6.8 73.2% 160 2.99 68.1%
350 7.6 71.5% 5/32 140 3.11 75.0%
170 3.78 73.5% Turn Pages
200 4.31 73.0%
Lesson 6
3/16 200 4.85 76.4% Request
Carbon & Low Alloy E7024 250 5.36 74.6% Certificate
Steel Filler Metals - ELECTRODE DEPOSITION EFFICIENCY 300 5.61 70.3% After
GMAW,GTAW,SAW DIAMETER AMPS RATE lbs/hr % 7/32 250 6.50 75.0%
Completion
1/8 140 4.2 71.8% 300 7.20 74.0%
Lesson 7 180 5.1 70.7% 350 7.40 73.0% Search
Flux Cored Arc 5/32 180 5.3 71.3% 1/4 300 7.72 78.0% Chapter
Electrodes Carbon 210 6.3 72.5% 350 8.67 77.0% (Faster
240 7.2 69.4% 400 9.04 74.0% Download)
Low Alloy Steels
3/16 245 7.5 69.2%
Search
270 8.3 70.5%
290 9.1 68.0% Document
Lesson 8 (Slower
7/32 320 9.4 72.4%
360 11.6 69.1%
Electrodes 1/4 400 12.6 71.7%
Lesson 9
Estimating & DEPOSITION DATA - SMAW - COATED ELECTRODES (Con't.)
Comparing Weld FIGURE 9
Metal Costs
NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

Lesson 10
Filler Metals
0.045 Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
9.3.2 FLUX CORED ARC WELDING/METAL CORED ARC WELDING - Deposition

Lesson 2
data for gas shielded FCAW on all low alloy wire types and MCAW on all alloy types.
Common Electric
Arc Welding
Processes
FLUX CORED ARC WELDING (FCAW)
GAS SHIELDED TYPES E70T-1, E71T-1, E70T-2,
Go To Test
Lesson 3 E70T-5, & ALL LOW ALLOY TYPES
Covered Electrodes ELECTRODE DEPOSITION EFFICIENCY METAL CORED ARC WELDING (MCAW)
Print
for Welding DIAMETER AMPS RATE lbs/hr % E70T-1, E71T-1, AND ALL ALLOY TYPES
Mild Steels .035 130 3.2 82% ELECTRODE DEPOSITION EFFICIENCY
140 3.6 82% DIAMETER AMPS RATE lbs/hr %
Lesson 4 160 4.2 83% 0.035 150 4.4 93% Glossary

Covered Electrodes 180 5.6 83% 200 6.5 92%
200 6.5 84% 250 9.4 92%
for Welding Low
220 7.5 85% 250 8 91%
Alloy Steels 275 11.4 93%
.045 160 4.0 83%
300 11.6 95%
180 4.9 87%
Lesson 5 0.052 275 8 90%
200 6.5 90%
300 9.6 93%
Welding Filler Metals 220 6.8 84% 325 10.1 93%
for Stainless Steels 240 7.3 84% 1/16 300 8.6 89%
280 10.5 89% 350 11.9 94%
Turn Pages
.052 170 3.9 84% 400 14.6 93%
Lesson 6 190 5.3 87% 450 16.2 96%
5/64 350 11.6 94% Request
Carbon & Low Alloy 210 5.5 86%
400 13.2 95% Certificate
Steel Filler Metals - 240 6.7 85%
450 15.8 97% After
GMAW,GTAW,SAW 270 8.1 85%
500 20.4 97% Completion
300 10.3 87% 3/32 400 11.5 95%
Lesson 7 1/16 180 4.2 87% 450 14.5 97% Search
Flux Cored Arc 200 4.7 85% 500 16.5 97% Chapter
Electrodes Carbon 220 5.6 87% 550 21 98% (Faster
250 7.7 86% Download)
Low Alloy Steels
275 8.5 86% NOTE: DATA REFLECTS USE OF 75% ARGON
25% CO2 GAS SHIELDING. DEPOSITION RATES
Search
300 9.3 86%
AND EFFICIENCIES WILL INCREASE WITH THE USE Document
Lesson 8 350 11.7 86%
OF HIGHER ARGON MIXTURES. (Slower
Hardsurfacing 5/64 250 6.4 85%
Download)
Electrodes 350 10.5 85%
450 14.8 85%
3/32 400 12.7 85%
Lesson 9 450 15.0 86%
Estimating & 500 18.5 86%
Comparing Weld
Metal Costs DEPOSITION DATA - FCAW/MCAW
FIGURE 10
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding GAS METAL ARC WELDING
9.3.3 FLUX CORED ARC WELDING,
Contents
SOLID WIRES
GAS METAL ARC WELDING, AND SUB- DEPOSITION RATE lbs/hr

Lesson 2 ELECTRODE 98%A/2%O2
75%A/25%CO2
Straight CO2
MERGED ARC WELDING - Deposition data DIAMETER AMPS *98% *96% *93%
Common Electric
for self-shielded FCAW, and solid wires using .030 75 2.0 1.9 1.8
Arc Welding 100 2.6 2.6 2.5
Processes GMAW and SubArc. 150 4.1 4.0 3.9
200 6.8 6.7 6.5
.035 80 2.2 2.1 2.0 Go To Test
Lesson 3 100 2.7 2.7 2.6
Covered Electrodes 150 4.2 4.1 4.0
200 6.2 6.0 5.9 Print
for Welding
250 9.0 8.8 8.6
Mild Steels .045 100 2.1 2.0 1.9
FLUX CORED ARC WELDING (FCAW) 125 2.8 2.8 2.7
SELF-SHIELDED 150 3.6 3.5 3.4
Lesson 4 200 5.6 5.5 5.3 Glossary
Covered Electrodes 250 7.8 7.6 7.4
ELECTRODE DEPOSITION EFFICIENCY
for Welding Low DIAMETER AMPS RATE lbs/hr %
300 10.2 10.0 9.7
350 13.2 12.9 12.5
Alloy Steels E70T-3 3/32 450 14 88%
1/16 250 6.5 6.4 6.2
E70T-4 3/32 400 15 85% 275 7.7 7.6 7.3
0.12 450 20 81% 300 9.0 8.8 8.5
Lesson 5
350 11.9 86% 350 11.3 11.0 10.7
Welding Filler Metals E70T-6 5/64
400 14.0 13.7 13.3
for Stainless Steels 3/32 480 14.7 81%
450 17.4 17.1 16.5
E70T-6 3/32 325 11.4 80%
* USE THIS FIGURE AS THE DEPOSITION EFFICIENCY IN THE
7/64 450 18 86% COST CALCULATIONS ON SHEET ONE. Turn Pages
E71T-7 .068 200 4.2 76%
Lesson 6 SUBMERGED ARC WIRES
5/64 300 8 84% Request
Carbon & Low Alloy (1" STICKOUT)
E71T-8 5/64 220 4.4 77% Certificate
Steel Filler Metals - ELECTRODE MELT-OFF EFFICIENCY
3/32 300 6.7 77% After
GMAW,GTAW,SAW DIAMETER AMPS RATE lbs/hr %
E61T8-K6 5/64 235 4.3 76% Completion
5/64 300 7.0
E70T-10 .045 150 2.6 88%
Lesson 7 400 10.2 Search
1/16 220 3.3 78% 500 15.0
5/64 250 4 94% 3/32 400 9.4
E71T-11 .045 150 2.4 82% 500 13.0 Assume
Low Alloy Steels 600 17.2 Download)
1/16 200 3.6 83%
1/8 400 8.5 99%
5/64 240 4.5 87% Search
500 11.5
3/32 250 5 91% Document
Lesson 8 600 15.0
300 14 83% Efficiency (Slower
E70T4-K2 3/32 700 19.0
E71T-GS .030 100 1.6 75% 5/32 500 11.3
Electrodes 120 2.1 84% 600 14.6
.035
700 18.4
.045 150 2.4 82%
800 22.0
1/16 200 3.6 83%
Lesson 9 900 26.1
5/64 250 3.9 81% 3/16 600 13.9
Estimating &
700 17.5
Comparing Weld 800 21.0
Metal Costs 900 25.0
DEPOSITION DATA 1000 29.2
1100 34.0
FIGURE 11
Lesson 10 NOTE: Values for 1" Stickout
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding 9.4 COST CALCULATIONS - EXAMPLE 1 Contents
9.4.1 Calculating the Cost Per Pound of Deposited Weld Metal

Lesson 2
Common Electric
9.4.1.1 Example 1 - Calculate the cost of welding 1,280 ft. of a single bevel butt joint as
Arc Welding
shown in Figure 14 using the following data.
Processes
a. Electrode - 3/16” diameter, 14” long, E7018, operated at 25 volts, 250 amps. Go To Test
Lesson 3
b. Stub Loss - 2 inches
Covered Electrodes
c. Labor and Overhead - $30.00/hr Print
for Welding
Mild Steels d. Electrode Cost - $.57/lb
e. Power Cost - $.045/kWh
Lesson 4 Glossary
Covered Electrodes 9.4.1.2 The formulas for the calculations are shown on the Weld Metal Cost Worksheet in
for Welding Low
Figure 12. The following explains each step in the calculations.
Alloy Steels
Line 1- Labor and Overhead - $30.00/hr (given)
Lesson 5 Deposition Rate - From shielded metal arc welding deposition data chart in
Figure 9 = 5.36 lbs/hr.
Operating Factor - Since it is not stated above, use an average value of 30% (.30)
shown in Figure 2. Turn Pages
Lesson 6 The cost of labor and overhead per pound of deposited weld metal can now be
Request
Carbon & Low Alloy calculated as $18.66/lb. Certificate
After
GMAW,GTAW,SAW
Line 2 - Electrode Cost Per Pound - $.57 (given) Completion
Lesson 7 Deposition Efficiency - From the shielded metal arc welding deposition table in Search
Flux Cored Arc Figure 9 = 74.6%. Since this is a coated electrode, the efficiency must be adjusted Chapter
Electrodes Carbon for stub loss by the formula following Figure 3. We know that the electrode length is
(Faster
14" and the stub loss is 2" (given). The formula becomes:
Search
Efficiency - Stub Loss = (14-2) x .746 ÷ 14 = .639 or 63.9%
Document
Lesson 8 63.9% is the adjusted efficiency to be used in Line 2.
(Slower
Hardsurfacing The cost of the electrode per pound of deposited weld metal can now be calculated Download)
Electrodes as $.89/lb.
Lesson 9 Line 3 - Not applicable for coated electrodes.

Estimating &
Comparing Weld Line 4 - Not applicable for coated electrodes.
Metal Costs
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
EXAMPLE 1
Lesson 2 WELD METAL COST WORKSHEET
Common Electric COST PER POUND OF DEPOSITED WELD METAL
Arc Welding
Processes
1.
30.00 30.00 Go To Test
LABOR & LABOR & OVERHEAD COST/HR = = = 18.66
Lesson 3 5.36 x .30 1.608
OVERHEAD DEPOSITION OPERATING
Covered Electrodes RATE (LBS/HR) x FACTOR
Print
for Welding
Mild Steels 2. .57
ELECTRODE ELECTRODE COST/LB = = .89
DEPOSITION EFFICIENCY .639
Lesson 4 Glossary
Covered Electrodes 3. GAS FLOW RATE
GAS N A
(CU FT/HR) x GAS COST/CU FT = = =
for Welding Low
DEPOSITION RATE (LBS/HR)
Alloy Steels
4. X 1.4 N A
FLUX FLUX COST/LB x 1.4 = = =
Lesson 5 DEPOSITION EFFICIENCY
.045 x 25 x 250 281.25 .052
for Stainless Steels 5. COST/kWh x VOLTS x AMPS = = =
POWER 1000 x DEPOSITION RATE 1000 x 5.36 5,360
Turn Pages
Lesson 6
6.
TOTAL COST PER LB. OF SUM OF 1 THROUGH 5 ABOVE
$ 19.60 Request
Carbon & Low Alloy DEPOSITED WELD METAL
Certificate
After
GMAW,GTAW,SAW
Completion
COST PER FOOT OF DEPOSITED WELD METAL Search
Lesson 7
7.
Electrodes Carbon COST PER POUND POUNDS PER (Faster
= 19.60x .814 = $15.95
OF DEPOSITED X FOOT OF Download)
Low Alloy Steels WELD METAL WELD JOINT
Search
Document
Lesson 8 COST OF WELD METAL - TOTAL JOB (Slower
Electrodes 8.
= 1,280x 15.95 = $20,422
TOTAL FEET X COST PER
OF WELD FOOT
Lesson 9
Estimating &
Comparing Weld
FIGURE 12
Metal Costs
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding Line 5 - Cost of Power - $ .045/kWh (given). Contents
Volts & Amperes - 25V and 250A (given).
Lesson 2 Constant - The 1,000 already entered, is a constant necessary to convert to
Common Electric watt-hours.
Arc Welding
Deposition Rate - 5.36 lbs/hr as used in Line 1.
Processes
The cost of electrical power to deposit one pound of weld metal can now be
Go To Test
calculated as $.052.
Lesson 3
Covered Electrodes
Line 6 - Total Lines 1, 2, and 5 to find the total cost of depositing one pound weld Print
for Welding
Mild Steels metal. The total of $19.60.
Lesson 4 9.4.2 Calculating The Cost Per Foot of Deposited Weld Metal Glossary
Covered Electrodes
for Welding Low Calculating the weight of weld metal requires that we consider the following items.
Alloy Steels
a. Area of the cross-section of the weld.
Lesson 5
b. Length of the weld.
for Stainless Steels c. Volume of the weld in cubic inches.
Turn Pages
d. Weight of the weld metal per cubic inch.
Lesson 6
Request
Carbon & Low Alloy 9.4.2.1 In the fillet weld show in Figure 13, we know that the area of the cross-section (the
Certificate
Steel Filler Metals - triangle) is equal to one-half the base times the height, the volume of the weld is equal to the After
GMAW,GTAW,SAW
area times the length, and the weight of the weld then, is the volume times the weight of the Completion
material (steel) per cubic inch. Search
Lesson 7
9.4.2.2 We can then write the formula: (Faster
Electrodes Carbon
Weight of Weld Metal = ½ x Base x Height x Length x Weight of Material
Search
Document
Lesson 8 Substituting the values from Figure 13, we have:
(Slower
Hardsurfacing Wt/Ft = .5 x .5 x .5 x 12 x .283 = .4245 lbs Download)
Electrodes
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 calculations for
Lesson 9 steel fillet and butt joints, since it lists the weight per foot directly.
Estimating &
Comparing Weld 9.4.2.4 Estimating the weight per foot of a weld using the chart, requires that you make a
Metal Costs
drawing of the weld joint to exact scale, and dimension the leg lengths, root gap, thickness,
angles and other pertinent measurements as shown in Figure 15. Divide the cross-section of
Lesson 10 the weld into right triangles and rectangles as shown. Sketch in the reinforcement, i.e., the
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
Lesson 2
Common Electric
Arc Welding
(A) 1/2"
Processes HEIGHT
Volume of Weld = 1/2 B x A x 12 Go To Test

Lesson 3 1/2" Weight of Steel = .283 lb per cu. in.
Weight of Weld = 1/2 (1/2) x 1/2 x 12 x .283
Covered Electrodes (B) BASE = .424 lbs.
Print
for Welding
Mild Steels CALCULATING THE WEIGHT PER FOOT OF A FILLET WELD
FIGURE 13
Lesson 4 Glossary
Covered Electrodes
for Welding Low
Alloy Steels
domed portion above or below the surface of the plate, where required. The reinforcement
Lesson 5 should extend slightly beyond the edges of the joint. Measure the length 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. Turn Pages
Lesson 6 The sum of the weights of all the components is the total weight of the weld, per foot as shown
Request
Carbon & Low Alloy in Figure 15A. Certificate
After
GMAW,GTAW,SAW Line 7 - The total cost per pound as determined in Line 6 is entered, and multi- Completion
plied by the weight per foot as determined in Figure 14. Search
Lesson 7
Flux Cored Arc 9.4.3 Calculating the Cost of Weld Metal - Total Job Chapter
Low Alloy Steels Line 8 - The cost of the weld for the total job is determined by multiplying the total Download)
feet of weld (given) by the cost per foot as determined in Line 7. Search
Document
Lesson 8 (Slower
Hardsurfacing
9.5 COST CALCULATIONS - EXAMPLE 2 Download)
Electrodes
Calculate the total cost of depositing 1,280 ft of weld metal using the CO2 shielded, flux cored
Lesson 9 welding process in the double V-groove joint shown in Figure 14 using the following data.
Estimating &
Comparing Weld 1. Electrode - 3/32”, E70T-1 @ 31 volts, 450 amps.
Metal Costs 2. Labor and Overhead - $30.00/hr.
3. Deposition Rate - 15 lbs/hr. From Table in Figure 10.
Lesson 10 4. Operating Factor - 45% (.45). Average from Figure 2.

Filler Metals
V-GROOVE
Current
Lesson 1
Chapter
The Basics of Arc LESSON IX
Table of
Welding
WEIGHT PER FOOT OF WELD METAL FOR FILLET WELDS AND Contents
ELEMENTS OF COMMON BUTT JOINTS (lbs/ft)
STEEL
Lesson 2
Common Electric
Arc Welding
Processes S S S
G G
C C Go To Test
Lesson 3 T B B B
Covered Electrodes
B
T A T T A T
Print
for Welding
Mild Steels EQUAL LEG
C C
SINGLE SINGLE
FILLETS
BEVEL V-GROOVE
(USE 45°COLUMN)
Lesson 4 Glossary
Covered Electrodes
for Welding Low S S S S S
G G
Alloy Steels
C C C H
B B B
T T B B
A
Lesson 5 T A
T T
Welding Filler Metals B B B T
C
for Stainless Steels C
DOUBLE DOUBLE SINGLE V
REINFORCEMENT
BEVEL NO GAP Turn Pages
Lesson 6
lbs./ft. of Rectangle A lbs./ft. of Triangle B lbs./ft. Reinforcement C Request
Carbon & Low Alloy T G S H Certificate
Steel Filler Metals - Inches 1/16" 1/8" 3/16" 1/4" 3/8" 1/2" 5° 10° 15° 22 1/2° 30° 45° 1/16" 1/8" 3/16" 1/4"
After
GMAW,GTAW,SAW
1/8 .027 .053 .080 .106 .159 .212 .002 .005 .007 .011 .015 .027
Completion
3/16 .040 .080 .119 .159 .239 .318 .005 .011 .016 .025 .035 .060 .027
Lesson 7 1/4 .053 .106 .159 .212 .318 .425 .009 .019 .028 .044 .061 .106 .035
Search
5/16 .066 .133 .199 .265 .390 .531 .015 .029 .044 .069 .096 .166 .044 .884
Electrodes Carbon 3/8 .080 .159 .239 .318 .478 .637 .021 .042 .064 .099 .138 .239 .053 .106
(Faster
Low Alloy Steels 7/16 .091 .186 .279 .371 .557 .743 .028 .057 .087 .129 .188 .325 .062 .124 Download)
.106 .212 .318 .425 .637 .849 .037 .075 .114 .176 .245 .425 .071 .141 .212
9/16 .119 .239 .358 .478 .716 .955 .047 .095 .144 .223 .311 .451 .080 .159 .239 Search
5/8 .133 .265 .398 .531 .796 1.061 .058 .117 .178 .275 .383 .664 .088 .177 .265 .354 Document
Lesson 8 11/16 .146 .292 .438 .584 .876 1.167 .070 .142 .215 .332 .464 .804 .097 .195 .292 .389
3/4 .159 .318 .478 .637 .995 1.274 .084 .169 .256 .396 .552 .956 .106 .212 .318 .424 (Slower
13/16 .172 .345 .517 .690 1.035 1.380 .098 .198 .301 .464 .648 1.121 .115 .230 .345 .460
Electrodes 7/8 .186 .371 .557 .743 1.114 1.486 .114 .230 .349 .538 .751 1.300 .124 .248 .371 .495
15/16 .199 .398 .597 .796 1.194 1.592 .131 .263 .400 .618 .863 1.493 .133 .266 .398 .530
1 .212 .425 .637 .849 1.274 1.698 .149 .300 .456 .703 .981 1.698 .141 .283 .424 .566
Lesson 9 .239 .478 .716 .955 1.433 1.910 .188 .379 .577 .890 1.241 2.149 .159 .318 .477 .637
Estimating & 1 .265 .531 .796 1.061 1.592 2.123 .232 .468 .712 1.099 1.532 2.653 .177 .354 .531 .707
1
1/4 .292 .584 .876 1.167 1.751 2.335 .281 .567 .861 1.330 1.853 3.210 .195 .389 .584 .777
Comparing Weld 1
3/8 .318 .637 .955 1.274 1.910 2.547 .334 .674 1.023 1.582 2.206 3.821 .212 .424 .637 .849
1/2
Metal Costs
1 .345 .690 1.035 1.380 2.069 2.759 .393 .792 1.201 1.857 2.589 4.484 .230 .460 .690 .920
1
5/8 .371 .743 1.114 1.486 2.229 2.972 .455 .918 1.393 2.154 3.002 5.200 .248 .495 .743 .990
3/4 .390 .796 1.194 1.592 2.388 3.184 .523 1.053 1.599 2.473 3.447 5.970 .266 .531 .796 1.061
Lesson 10 2 .425 .649 1.274 1.698 2.547 3.396 .594 1.197 1.820 2.813 3.921 6.792 .283 .566 .849 1.132
Reliability of Welding 2 .478 .955 1.433 1.910 2.865 3.821 .752 1.516 2.303 3.561 4.963 8.596 .318 .637 .955 1.273
1/4 .530 1.061 1.592 2.123 3.184 4.245 .928 1.871 2.844 4.396 6.127 10.613 .354 .707 1.061 1.415
Filler Metals 2 .584 1.167 1.751 2.335 3.502 4.669 1.123 2.264 3.441 5.319 7.414 12.841 .389 .778 1.167 1.556
3
3/4 .636 1.274 1.910 2.547 3.821 5.094 1.337 2.695 4.095 6.330 8.823 15.282 .424 .849 1.273 1.698
FIGURE 14
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding 22.5° 22.5°
Contents
45°
Lesson 2 1/ C
7/8"
16"
Common Electric C
Arc Welding B 1/2"

Processes 5/8" A B 1/2"
1"
Go To Test
B
Lesson 3
Covered Electrodes 1/8"
A B C Print
for Welding 1/16"
lbs./ft.
Mild Steels 1/2"
A= .265 lbs./ft.
B= .425
C= .124 B = .176 x 4 = .704
Lesson 4 TOTAL WEIGHT/FT. .814 lbs C = .071 x 2 = .142
TOTAL WEIGHT/FT. .846 lbs Glossary
Covered Electrodes
ESTIMATING WELD METAL WEIGHT
for Welding Low
Alloy Steels FIGURE 15
Lesson 5 5. Electrode Cost - $.80/lb (from supplier).

Welding Filler Metals 6. Deposition Efficiency - 86% (.86) From Table in Figure 10.
for Stainless Steels 7. Gas Flow Rate - 45 cubic feet per hour. From Figure 7.
8. Gas Cost - $.03/cubic foot (from supplier). Turn Pages
Lesson 6 9. Cost of Power - $.045/kWh.
Request
Carbon & Low Alloy 10. Wt/Ft of Weld - From Figure 15B = .846 lbs/ft.
Certificate
Steel Filler Metals - These values are shown inserted into the formulas on the Weld Metal Cost Worksheet in After
GMAW,GTAW,SAW Figure 16. Completion
Lesson 7 Search
Flux Cored Arc 9.6 COMPARING WELD METAL COSTS Chapter
Low Alloy Steels It is interesting to note that the amount of weld metal deposited in Example 1 and Example 2 is Download)
almost the same, while the total cost of depositing the weld metal is three times higher in Search
Example 1 as shown below. This is because the flux cored process has a higher deposition Document
Lesson 8 (Slower
Hardsurfacing rate, efficiency and operating factor and also allows a tighter joint due to the deep penetrating
Download)
Electrodes characteristics of the process.
Example 1 - 1,280 ft x .814 lbs/ft = 1,041.9 lbs at $13,939

Lesson 9
Example 2 - 1,280 ft x .846 lbs/ft = 1,082.9 lbs at $ 4,352
Estimating &
Comparing Weld
9.6.0.1 When comparing welding processes, all efforts should be made to assure that you
Metal Costs
use the proper welding current for the electrode or wire in the position in which the weld must
be made. As an example, consider depositing a given size fillet weld in the vertical-up posi-
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
Contents
EXAMPLE 2
Lesson 2 WELD METAL COST WORKSHEET
Common Electric COST PER POUND OF DEPOSITED WELD METAL
Arc Welding
Processes
1.
30.00 30.00 Go To Test
LABOR & LABOR & OVERHEAD COST/HR = = = 4.44
Lesson 3 6.75
OVERHEAD DEPOSITION OPERATING 15 x .45
Covered Electrodes RATE (LBS/HR) x FACTOR
Print
for Welding
Mild Steels 2. .80
ELECTRODE ELECTRODE COST/LB = = .93
DEPOSITION EFFICIENCY .86
Lesson 4 Glossary
Covered Electrodes 3. GAS FLOW RATE
GAS (CU FT/HR) x GAS COST/CU FT
45 x .03 1.35
for Welding Low = = = .09
DEPOSITION RATE (LBS/HR) 1 5 1 5
Alloy Steels
4. x 1.4 NA
FLUX FLUX COST/LB x 1.4 = = =
Lesson 5 DEPOSITION EFFICIENCY
5. COST/kWh x VOLTS x AMPS .045 x 31 x 450 627.75 .042
for Stainless Steels POWER
= = =
1000 x DEPOSITION RATE 1000 x 15 15,000
Turn Pages
Lesson 6
6.
TOTAL COST PER LB. OF SUM OF 1 THROUGH 5 ABOVE $ 5.51 Request
Carbon & Low Alloy DEPOSITED WELD METAL
Certificate
After
GMAW,GTAW,SAW
Completion
COST PER FOOT OF DEPOSITED WELD METAL Search
Lesson 7
7.
Electrodes Carbon COST PER POUND POUNDS PER (Faster
OF DEPOSITED X FOOT OF = 5.51 x .846 = $4.66
Low Alloy Steels WELD METAL WELD JOINT
Download)
Search
Document
Lesson 8 COST OF WELD METAL - TOTAL JOB (Slower
Electrodes 8.
TOTAL FEET COST PER = 1,280x 4.66 = $5,965
X
OF WELD FOOT
Lesson 9
Estimating &
Comparing Weld
FIGURE 16
Metal Costs
Lesson 10
Filler Metals
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding
tion by the GMAW process and FCAW process semi-automatically. In both processes the Contents
welding current and voltage must be lowered to weld out-of-position, and in GMAW, the short
Lesson 2 circuiting arc transfer must be used. Example 3 compares the weld metal cost per pound
Common Electric deposited by these processes, using the proper current and voltage for depositing a ¼” fillet
Arc Welding
weld on ¼” plate, vertically up.
Processes
Note: The cost of electrical power is comparable in all processes and therefore, can be eliminated as a factor. Go To Test
Lesson 3
Covered Electrodes 9.6.1 Example 3
Print
for Welding
Mild Steels FCAW GMAW
Electrode Type - .045” dia. E71T-1 .045” dia. ER70S-3

Lesson 4 Glossary
Covered Electrodes Labor & Overhead - $30.00/hr $30.00/hr
for Welding Low Welding Current - 180 amperes 125 amperes
Alloy Steels
Deposition Rate - 4.9 lbs/hr (Fig. 9) 2.8 lbs/hr (Fig. 10)
Operating Factor - 45% (Fig. 2) 50% (Fig. 2)

Lesson 5
Welding Filler Metals Electrode Cost - $1.44/lb $.66/lb
Deposition Efficiency - 85% (Fig. 9) 96% (Fig. 6)
Gas Flow Rate - 35 cfh (Fig. 7) 35 cfh (Fig. 7) Turn Pages

Lesson 6
Gas Cost Per Cu. Ft. - $.03 CO2 $.11 75% Ar/25% CO2 Request
Carbon & Low Alloy
Certificate
After
GMAW,GTAW,SAW This data is tabulated in the chart in Figure 17. Completion
Lesson 7 Search
9.6.1.1 As you can see, the cost of depositing the weld metal is about 33% less using the
Flux Cored Arc Welding process. Since there is no slag to help hold the vertical weld puddle (Faster
Electrodes Carbon
in the GMAW process, the welding current with solid wire must be lowered considerably. This, Download)
Low Alloy Steels
of course, lowers the deposition rate, and since labor and overhead is the largest factor in- Search
volved, it substantially raises deposition costs. In the flat or horizontal position, where the Document
Lesson 8 (Slower
welding current on the solid wire would be much higher, the cost difference would be consider-
ably less pronounced.
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
Current
Lesson 1
Chapter
The Basics of Arc LESSON IX
Table of
Welding
Contents
The following information/variables must be determined prior to completing calculations:
(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation
Lesson 2 Flux Cored Arc Welding Gas Metal Arc Welding
E71T-1 .045 Dia. at 180 Amps (3)
Common Electric ER70S-3 .045 Dia. at 125 Amps (4)
Actual Labor & O/H Rate for your Customer
Arc Welding $ 30.00 Actual Labor & O/H Rate for your Customer $ 30.00
Deposition Rate in Pounds per Hour
4.9 Deposition Rate in Pounds per Hour 2.8
Processes Operating Factor
45% Operating Factor 50%
Electrode Cost per Pound
$ 1.44 Electrode Cost per Pound $ 0.66
Deposition Efficiency Go To Test
85% Deposition Efficiency 96%
Gas Type
Lesson 3 Gas Flow Rate
CO2 Gas Type 75% Ar/25% CO2
35 Gas Flow Rate 30
Covered Electrodes Gas Cost per Cubic Foot
$ 0.03 Gas Cost per Cubic Foot $ 0.11 Print
Equipment Cost
for Welding $ -
Mild Steels Prepared For: NAME INFO Customer Name: NAME INFO Date: Result
(1) Proposed Method Cost Calculation (2) Present Method Cost Calculation (Cost
Reduction )
Formulas for Calculating Flux Cored Arc Welding Gas Metal Arc Welding
Lesson 4 Cost
Cost per Pound Deposited Weld Metal E71T-1 .045 Dia. at 180 Amps ER70S-3 .045 Dia. at 125 Amps Increase Glossary
Covered Electrodes
Labor& = Labor & Overhead Cost /Hr = $30.00 = $30.00 = $13.605 $30.00 = $30.00 = $21.429 ($7.823 )
for Welding Low
Overhead Deposition Operating 4.9 X 0.45 = 2.205 2.8 X 0.5 = 1.4
Alloy Steels X
Rate Factor
(lbs / hr)
Electrode Electrode Cost/lb = 1.44 = 1.694 0.66 = 0.688 $1.007
Lesson 5 Deposition Efficiency 0.85 0.96
Welding Filler Metals Gas Type = CO2 Gas Type = 75% Ar/25% CO2
Gas Flow Rate (Cuft/hr)
for Stainless Steels Gas
X Gas Cost/Cu ft. = 35 X 0.03 = 1.05 = 0.214 3 0 X 0.11 = 3.3 = 1.179 ($0.964 )
Deposition Rate (lbs&/hr) 4.9 2.8
Turn Pages
Total Variable Cost/lb Total Variable Cost/lb
Lesson 6 Sum of the Above = $15.514 Deposited Weld Metal = $23.295 ( $7.781)
Deposited Weld Metal Request
Carbon & Low Alloy T otal
Certificate
After
GMAW,GTAW,SAW
Completion
Lesson 7 9.7 OTHER USEFUL FORMULAS Search

The information discussed below will assist you in making other useful calculations:
TOTAL POUNDS OF ELECTRODES REQUIRED (REF. EXAMPLE 1) Search

Document
Lesson 8 (Slower
Hardsurfacing Wt/Ft of Weld x No. of Ft of Weld
Total Pounds = Download)
Electrodes
Deposition Efficiency
Lesson 9 .814 x 1,280

Estimating &
Substituting the values from Example 1: = 1,631 lbs
.630
Comparing Weld
Metal Costs
WELDING TIME REQUIRED (REF. EXAMPLE 1)
Lesson 10
Wt/Ft of Weld x Ft of Weld
Reliability of Welding Welding Time =
Filler Metals Deposition Rate x Operating Factor
.814 x 1,280 1,042

Substituting the values in Example 1: = = 648 Hrs.
5.36 x .30 1.608
Current
Lesson 1
LESSON IX Chapter
The Basics of Arc
Table of
Welding 9.8 AMORTIZATION OF EQUIPMENT COSTS Contents
Calculations show that you can save $7.00 per pound of deposited weld metal by switching
Lesson 2
Common Electric from E7018 electrodes and the SMAW process to an ER70S0-3 solid wire using the GMAW
Arc Welding process. However, the cost of the necessary equipment (power source, wire feeder and gun)
Processes is $2,800. How long will it take to amortize or regain the cost 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 Go To Test
Lesson 3 is 50%? The formula is:
Covered Electrodes
Print
for Welding Equipment Cost
Mild Steels
$ Savings/Lb
÷ (Deposition Rate x Operating Factor) = Man Hrs
Lesson 4 Glossary
Covered Electrodes 2,800
for Welding Low
Substituting the values in the formula:
7.00 ÷ (7.4 x .50) = Man Hrs
Alloy Steels
400 ÷ 3.7 = Man Hrs

Lesson 5
If we divide 108 into eight hour days (108 ÷ 8 = 13.5) 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.
Turn Pages
Lesson 6
Request
Carbon & Low Alloy
Certificate
After
GMAW,GTAW,SAW
Completion
Lesson 7 Search
Search
Document
Lesson 8 (Slower
Electrodes
Lesson 9
Estimating &
Comparing Weld
Metal Costs
Lesson 10
Filler Metals
Lesson 9 Test
Worksheet for Check Your Close

Problem #1 Answers! Window
LESSON IX - TEST QUESTIONS

ESTIMATING AND COMPARING WELD METAL COSTS
1. Labor and overhead account for approximately ____of the total cost of depositing metaI.
a) 20% b) 15%
c) 85%
2. Deposition rate decreases as welding current increases.

a) True b) False
3. When welding with solid or flux cored wires, the deposition rate will increase as the
electrical stick-out is increased, at the same amperage.
a) True b) False
4. An operating factor of 33% means that the operator is actually welding approximately
______hours if he works a nine (9) hour day
a) 3 b) 4-1/2
c) 6
5. The deposition efficiency tells us approximately the number of pounds of weld metal we
may expect from each 100 pounds of solid or flux cored wire purchased.
a) True b) False
6. A manufacturer of coated electrodes states that at a given amperage, the efficiency of

an 18" long electrode is 75%. Assuming a 3" stub loss, the efficiency minus stub loss
would be
a) 69.5% b) 71.2%
c) 62.5% d) 71.1%
7. In gas metal arc welding, spatter loss decreases as the percentage of argon in the
shielding gas
a) decreases b) increases
8. The cost of electrical power is a large factor in calculating weld metal costs.
a) True b) False
9. The weight per ft of a 3/8" equal leg length fillet weld (steel) is ______pounds per ft.
a) .050 b) .475
c) .239
o o
22.5 1" 22.5
10. The weight per ft of this single V-groove butt weld is ______ pounds per ft.
a) 2.008 b) .975 1" 7/8"
1/8"
c) 1.754
1/8"
Diagram Question 10
1/8"
30o 30 o
11/16"
1.5"
11. The weight per ft of this double V-groove butt weld is _______ pounds per ft.
a) 3.129 b) 5.250 11/8"
1/8"
c) 2.999 30o 30o
Diagram Question 11
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Lesson 9 Test
12. From line 1 of your worksheet, what is the cost of labor

and overhead per lb of deposited weld metal?
Reference Information
a) $7.94 b) $1.95
c) $4.50 d) $9.24 A customer wants to know how much it will cost
to weld 1,000 ft of 1/2” horizontal fillet, using a
1/4” E7024 electrode at 26 volts, 400 amps. Use the
13. From line 2 of your worksheet, what is the electrode weld metal cost worksheet at the back of this lesson
cost to deposit 1 lb of weld metal? to work out this problem with the following
(Don’t forget stub loss calculation.) given data, and using the various charts and
a) $.755 b) $.934 average values for the unknown factors.
c) $1.30 d) $.S9
Given: Labor & Overhead - $30.00 per hour
Electrode Cost/Lb - $.755/Ib
14. From line 5 of your worksheet, what is the cost of
Electrical Power Cost - $.035/kWh
electrical power to deposit 1 lb of weld metal?
Electrode Length - 18"
a) $.89 b) $.10 (assume 3" stub loss)
c) $.25 d) $.029
Answer questions 12 thru 15 as they pertain

15. From line 8 of your worksheet ,what is the cost of to your worksheet.
weld metal for the total job? Select the closest answer since the values may
a) $2,170 b) $3,940 vary slightly due to differences in rounding off decimals.

Page 2
of Test

Lesson 9 Test - Page 2

Answer questions 16 thru 20 as they pertain to your worksheet.
16. From line 1 on your worksheet, what is the cost of labor Reference Information
and overhead per lb. of deposited weld metal?
a) $4.44 b) $1.25 Based on problem 1, this same customer, after
c) $3.00 d) $5.59 using the high deposition E7024 coated electrode,
asks if you can suggest a way to cut welding costs.
17. From line 2 on your worksheet, what is the cost of the Your suggestion might be to switch to the flux cored
electrode necessary to deposit 1lb of weld metal? process using a 3/32" diameter electrode
a) $.95 b) $1.37 at 31 volts and 450 amperes to do the same
c) $1.25 d) $.80 1,000 ft of 1/2"horizontal fillet weld. Use the worksheet
for Problem 2 and the following given parameters.
18. From line 3 on your worksheet, what is the cost of
shielding gas necessary to deposit 1lb of weld metal? Electrode - E70T-1, 3/32" dia. at
a) $.25 b) $.15 31 volts, 450 amps
c) $.09 d) $.01 Labor & Overhead - $30.00 per hour
Electrode Cost/LB -$1.179/Ib
19. From line 5 of your worksheet, what is the cost of Gas Flow Rate-45 cubic ft/hour
electrical power necessary to deposit 1 lb of weld metal? Gas Cost/Cubic Foot -$.03/cubicft (C02)
a) $.033 b) $.096 Power Cost - $.035/kWh
c) $.015 d) $.33
20. From line 8 of your worksheet, what is the cost

of weld metal for the total job?
a) $2,000 b) $5,290
c) $2,520
21. If you answered all questions in both Problem 1 and 2 correctly, your figures should
show that the saving in the cost per lb of deposited weld metal is $3.27 by using the flux
cored process. Using this figure in the formula in section 9.7, how many hours will it
take to recover the $2,500 necessary to pay for the new equipment for this process?
a) 193 b) 301
c) 127 d) 275
22. Using the formula found in section 9.7

9.7 OTHER USEFUL FORMULAS
(Other Useful Formulas), how many pounds of
The information discussed below will assist you in making
E7024 electrode are needed to deposit the 1,000 ft of weld?
other useful calculations:
a) 1,500 lbs b) 729 lbs
c) 600 lbs TOTAL POUNDS OF ELECTRODES REQUIRED
Wt/Ft of Weld x No. of Ft of Weld
Total Pounds = Deposition Efficiency
23. Using the same formula in section 9.7
(Other Useful Formulas), how many pounds of E70T-1 Substituting values: .814 x 1,280 = 1,631 lbs
electrode are needed for the required 1,000 ft of weld? .630
a) 500 lbs b) 980 Ibs
WELDING TIME REQUIRED
c) 494 lbs
Wt/Ft of Weld x Ft of Weld
Welding Time = Deposition Rate x Operating Factor
Substituting values:
.814 x 1,280 1,042
5.36 x .30 = 1.608 = 648 Hrs.

Lesson 9 Test - Page 2

Page 1
of Test

Answer Key - Lesson 9
CORRECT
ANSWER LOCATION IN TEXT COMMENT
1. c) Para 9.1
2. b) Para 9.2.2
3. a) Para 9.2.2.1
4. a) Para 9.2.3
5. a) Para 9.2.4.1
6. c) Para 9.2.5, Figure 3 & 4
7. b) Para 9.2.7
8. b) Para 9.2.10
9. c) Para 9.4.2, Para 9.4.2.2,

Figure 13 & 14
10. c) Para 9.4.2, Ref Chart, Figure 14
.425 + 2(.538) + .283 = 1.784
11. a) Para 9.4.2, Ref Chart, Figure 14

.637 +4(.464) +2(.318) = 3.129
12. a) 30 = 7.94
12.6 x .30
13. c) .755 = 1.30

.58
14. d) .035 x 26 400 = .029
1000 x 12.6
15. b) 9.27 x 4.25 = 3.94 x 1000 = $3,940
16. a) 30.00 = 4.444

15 x .45
17. b) 1.18 = 1.37

.86
18. c) 45 x .03 = .09

15
19. a) .035 x 31 x 450 = .033

1000 x 15
20. c) 5.93 x 4.25 = 2.52 x 1000 = $2,520
21. b) .425 x 1000 = 729 lbs.

.583
22. c) .425 x 1000 = 494 lbs.

.86
23. c) 2800 ÷ (15 x .45) = 838 ÷ 6.75 = 124 man hrs.

3.34
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Answer Key - Lesson 9
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Lesson 9 - Estimating & Comparing Weld Metal Costs

©COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 4 9.2.1 Labor & Overhead ......................................................................................... 2

9.8 Amortization of Equipment Costs .......................................................... 21

Appendix C Problem 2 Worksheet ................................................................................ 27

© COPYRIGHT 2000 THE ESAB GROUP, INC.

9.2 FACTORS FOR COST FORMULAS Go To Test

for Stainless Steels Small Shops $10.00 to $25.00/hr.

current is increased. Search

© COPYRIGHT 2000 THE ESAB GROUP, INC.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Filler Metals -4-

Lesson 7 12 x .75 Search

© COPYRIGHT 2000 THE ESAB GROUP, INC.

60% 50.0% 45.0% 40.0% 35.0%

Lesson 4 65% 57.7% 54.2% 50.5% 46.9%

for Welding Low 75% 66.6% 62.5% 58.3% 54.2%

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 4 98% Ar - 2% O2 97 - 98.5% 98% Glossary

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Comparing Weld FIGURE 8

NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

© COPYRIGHT 2000 THE ESAB GROUP, INC.

NOTE: EFFICIENCY RATES DO NOT INCLUDE STUB LOSS

© COPYRIGHT 2000 THE ESAB GROUP, INC.

9.3.2 FLUX CORED ARC WELDING/METAL CORED ARC WELDING - Deposition

Lesson 4 160 4.2 83% 0.035 150 4.4 93% Glossary

© COPYRIGHT 2000 THE ESAB GROUP, INC.

GAS METAL ARC WELDING, AND SUB- DEPOSITION RATE lbs/hr

© COPYRIGHT 2000 THE ESAB GROUP, INC.

9.4.1 Calculating the Cost Per Pound of Deposited Weld Metal

Lesson 9 Line 3 - Not applicable for coated electrodes.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Volume of Weld = 1/2 B x A x 12 Go To Test

Lesson 10 4. Operating Factor - 45% (.45). Average from Figure 2.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Arc Welding B 1/2"

Lesson 5 5. Electrode Cost - $.80/lb (from supplier).

Example 1 - 1,280 ft x .814 lbs/ft = 1,041.9 lbs at $13,939

© COPYRIGHT 2000 THE ESAB GROUP, INC.

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Electrode Type - .045” dia. E71T-1 .045” dia. ER70S-3

Operating Factor - 45% (Fig. 2) 50% (Fig. 2)

Gas Flow Rate - 35 cfh (Fig. 7) 35 cfh (Fig. 7) Turn Pages

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Lesson 7 9.7 OTHER USEFUL FORMULAS Search

TOTAL POUNDS OF ELECTRODES REQUIRED (REF. EXAMPLE 1) Search

Lesson 9 .814 x 1,280

.814 x 1,280 1,042

© COPYRIGHT 2000 THE ESAB GROUP, INC.

400 ÷ 3.7 = Man Hrs

© COPYRIGHT 2000 THE ESAB GROUP, INC.

Worksheet for Check Your Close

LESSON IX - TEST QUESTIONS

2. Deposition rate decreases as welding current increases.

6. A manufacturer of coated electrodes states that at a given amperage, the efficiency of

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12. From line 1 of your worksheet, what is the cost of labor

Answer questions 12 thru 15 as they pertain

Worksheet for Check Your Close

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Worksheet for Check Your Close