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Process 1
Longitud de pierna (in) 1.000 Leg Size (in)
Material de aporte Carbon Steel Filler material
Process 2
0.250
Carbon Steel
FCAW (Gas)
Co2
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
Labor Cost Welding Wire Cost
73% Welding Wire Cost
14% Gas Cost
Gas Cost Power Cost
6%
Power Cost
7%
Labor Cost
Labor Cost Welding Wire Cost
86% Welding Wire Cost Gas Cost
9%
Power Cost
Gas Cost
5%
Power Cost
0%
DETERMINING WELDING COST FOR A SINGLE-V GROOVE WELD
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
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
93%
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" = 0.5625 in Process Efficiency 62% Process SMAW (14" Stick)
Distance "R" = 0.6867 in Welder Efficiency 30% Bottles of gas needed N/A
Distance c1 = 0.7877 in Arc Time 0.40 hr Radius of cap "r" 2.907207
Distance "c" = 0.8502 in Total welding time 1.34 hr Deposited Weld Metal Wt. 2
Filler Density lb/in^3 0.283 lb/in^3 Density of gas 0 lb/ft^3
Area Cap "C" 0.0177 in^2 Volume of gas in one 0.00 ft^3
Weld Metal Weight "C" 0.0602 lb/ft bottle
Area Rectangle "A" 0.0391 in^2 Total gas needed 0.00 ft^3
Weld Metal Weight "A" 0.133 lb/ft Labor Cost $ 49.89
Area of two Triangles "B" 0.2215 in^2 Gas Cost $0.00
Weld Metal Weight "B" 0.752 lb/ft Cost Electrode $3.65
Total Weld Metal Weight 0.9453 lb/ft Total Cost $ 53.84
Amount of Welding Wire 2.90 lb Final Cost $ 8.08 $ 61.92
Deposition Rate 7.20 Lb/hr Heat Input 76
Total Power Cost $0.30 Number of Passes 4
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