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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
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 $/ft
Power Cost; 0%
Process 2
0.250
200
21
190
0.045
Total Length of Weld(ft) 10
8
Gas Flow Rate (cfh) 40
50%
Cost Electrode($/lb) 2.5
60
Cost of Gas (per bottle) $70.00
Weight of gas (1 bottle) (lb) 50
Power Cost ($/kilowatt-hr) $0.15
Labor Cost
Welding Wire Cost
Gas Cost
Labor Cost; 73%
Power Cost
Welding Wire Cost; 14%
Gas Cost; 6%
Power Cost; 7%
Labor Cost
Labor Cost; 86%
Welding Wire Cost
Gas Cost
Power Cost
Process 1 Process 2
Thickness (in) 0.625 Thickness (in) 0.625
Height of "h" (in) 0.031 Height of "h" (in) 0.063
Root Opening (in) 0.063 Root Opening (in) 0.094
Root Face(in) 0.063 Root Face(in) 0.063
Process Process
Gas Used Gas Used
Amps 280 Amps
Volts 27 Volts
Wire Feed (in/min) 0 Wire Feed (in/min)
Wire Diam. (in) 0.094 Wire Diam. (in)
Joint Angle 70 Joint Angle
Total Length of Weld(ft) 1.9 Total Length of Weld(ft)
Travel Speed (ipm) 6 Travel Speed (ipm)
Gas Flow Rate (cfh) 0 Gas Flow Rate (cfh)
Welder Efficiency 30% Welder Efficiency
Cost Electrode($/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
200
20
225
0.05
60
1000
8
35
50%
2.25
60
$75.00
50
$0.12
Labor Cost
Welding Wire Cost
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Process 1 Process 2
Thickness (in) 2.25 Thickness (in) 2.25
Height of "h" (in) 0.09375 Height of "h" (in) 0.09375
Root Opening (in) 0.125 Root Opening (in) 0.125
Root Face(in) 0.09375 Root Face(in) 0.09375
Process Process
Gas Used Gas Used
Amps 200 Amps
Volts 21 Volts
Wire Feed (in/min) 225 Wire Feed (in/min)
Wire Diam. (in) 0.052 Wire Diam. (in)
Joint Angle 45 Joint Angle
Total Length of Weld(ft) 3.535 Total Length of Weld(ft)
Travel Speed (ipm) 9 Travel Speed (ipm)
Gas Flow Rate (cfh) 35 Gas Flow Rate (cfh)
Welder Efficiency 50% Welder Efficiency
Cost Electrode($/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
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%
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
in
lb
FCAW (Gas)
in
lb
FCAW (Gas)
in
lb
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