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Determining Welding Cost For A Fillet Weld: Project: Company: Subject: Welding Process Used
Determining Welding Cost For A Fillet Weld: Project: Company: Subject: Welding Process Used
Process 1 Process 2
Leg Size (in) 0.250 Leg Size (in) 0.250
Filler material Carbon Steel Filler material Carbon Steel
FCAW (Gas)
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
97%
Power Cost
0% Welding Wire Cost
2%
DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD
Process 1 Process 2
Thickness (in) 0.438 Thickness (in) 0.625
Height of "h" (in) 0.125 Height of "h" (in) 0.063
Root Opening (in) 0.125 Root Opening (in) 0.094
Root Face(in) 0.063 Root Face(in) 0.063
Carbon Steel
FCAW (Gas)
C25
200
20
225
0.05
60
1000
8
35
50%
2.25
60
$75.00
50
$0.12
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
98%
Welding Wire Cost
2%
Power Cost
0%
Labor Cost
Gas Cost Welding Wire Cost
5%
Gas Cost
Welding Wire Cost Power Cost
11% Labor Cost 0% Power Cost
84%
DETERMINING WELDING COST FOR A SINGLE-BEVEL GROOVE WELD
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
Carbon Steel
Labor Cost
Welding Wire Cost
Gas Cost
Power Cost
Labor Cost
98% Welding Wire Cost
2%
Power Cost
0%
Labor Cost
98% Welding Wire Cost
2%
Power Cost
0%
CALCULATIONS PROCESS 1 Single-V Groove
distance "d" = 0.375 in Process Efficiency 59% Process SMAW (12" Stick)
Distance "R" = 0.4578 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 0.5252 in Arc Time 5.05 hr Radius of cap "r" 0.485202
Distance "c" = 0.6502 in Total welding time 16.83 hr Deposited Weld Metal Wt. 6
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3
Area Cap "C" 0.0557 in^2 Volume of gas in one 0.00 ft^3
Weld Metal Weight "C" 0.1893 lb/ft bottle
Area Rectangle "A" 0.0547 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.186 lb/ft Labor Cost $ 595.66
Area of two Triangles "B" 0.0985 in^2 Gas Cost $0.00
Weld Metal Weight "B" 0.334 lb/ft Cost Electrode $13.48
Total Weld Metal Weight 0.7094 lb/ft Total Cost $ 610.91
Amount of Welding Wire 10.70 lb Final Cost $ 91.64 $ 702.55
Deposition Rate 2.12 Lb/hr Heat Input 35
Total Power Cost $1.77 Number of Passes 6
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% 1 3 Fillet 0.375
SMAW (14" Stick) 0.62 30% 4
SMAW (18" Stick) 66% 30% 3
7 5 Sing-V 3
5 8 Sing-Bev 3
8 5 Fillet 4
Interpolation of Deposit Single_V Interpolation of Deposit 3
Rate Process 1 5 Deposition Rates SMAW 7 Rate Process 1
0.000 0 110 1.8 0 0.000
0.000 0 125 2 125 2.120
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 0 0.000
0.000 0 325 9 0 0.000
6.076 400 10 2.120
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 8 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 3.700 200 200 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 0.000 0 325 9 0 0
1.8125 3.700 400 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 6 9
Single Bevel 27 27
Fillet Weld 3 3
4
2
2
3
4
3