Fillet Weld Cost Analysis Tool

Copyright by Neal Chapman, Sterling Weld Data Systems 1995, 2002

The following spreadsheet can be used to estimate the cost of a Fillet Weld. The estimate is based on filler
materials, direct labor, joint dimensions, gas, and power cost inputs. The following figure depicts the weld
configuration and numbers that correlate to the user input values.

The red figures are inputs that are to be entered or changed by the user. The blue figures are calculated
values and are used to document costs. These values are to be reviewed to determine the effects of the
input values.

One of the best alternate uses of this application is to show to welders and supervisors the added costs of
overwelding. Check out the cost differences by adding an extra 1/16" or 1/8" to the prescribed size or
adding 10% oversize to the weld.

User Inputs Values Cost Outputs Values

Leg Size (in.) 0.187 Weight of Weld (lbs) 0.06
Length (in.) 12 Filler Required (lbs) 0.06
Size variation (%) 0% Arc On Hours 0.03
No. of joints 1 Labor Hours 0.07
Filler Density (lb/in3) 0.283 Total Filler cost ($) 0.12
Labor ($/hr) 35 Labor cost ($) 2.38
Filler cost ($/lb) 2 Total gas cost ($) 0.12
Gas Cost ($/CFH) 0.12 Power Costs($) 0.02
Gas Flow (CFH) 30 Total Cost ($) 2.65
Process Eff (%) 98%
Welder Eff (%) 50%
Avg. Amps 220
Avg. Volts 27
Power Cost ($/kwh) 0.12
**
Variation
Deposit Rate (lb/hr) 1.78
Length

Leg Size