eg. A wire 65% efficient at $2.50/Ky $3.85/Kg. of weldnetal, vs. A wire of 95% efficiency at $3,50/Kg $3.68/kg of weldmetal, NOTE Wire/flux combinations must include cost considerations for both wire and flux. tse, Consumable cost for a submerged arc welded joint. $/Kg wire x weight of weld metal ? wire efficiency factor, 3 $/kg flux x weight of weld metal i flux effictency factor. = TOTAL CONSUMABLE cosT, Table 3 lists efficiency factors for commonly encountered Consumables, 2.3 CALCULATION OF SHIELDING cost. SARCULATION OF SHIELDING COST. ARCTIME crsmncesa ron (7) $ The actual arc time 1s used as the as 1s only flowing when the arc is on. The constant 16.7 is used to convert flow in l/min to cubic metres/hour. The factor is derived trons 1000 lycubic metre = 16,7 60 min/hour.For the gas price divide net cost of the container by its Tabig ag. Mot 7, Fer S-i-G. cyiinuges, capacities are |faxew ip Table Oa,i8 gold by weinht. The stmospheric volume oe 1 kg of COZ is 0.842 m? (see Table 4) 3. OTHER COSTS. 3.1 AMORTIZING CAPITAL EXPENSE, | AMORTIZING CAPITAL EXPENSE, The opportunity for productivity gain may tavolve the purchase of new process equipment, positioners, floor space or duplicating existing facilities. A cost estimation of the proposed procedure will indicate the saving to be made against which the capital outlay can be paid. Amortize the cost over an appropriate period fe, tife or contract or tax depreciation period or leasing period. Ge? CONSUMABLES. There are hidden costs that may be significant dependant upon the Specific situation. These include such things as Ancilliary equipment Preheat Fuel Gouging and Grinding Consumables Cable and Protective Clothing Work scheduling losses and overtime. These factors could be added to the relevant sections, 4 RELATIONSHIP BETWEEN vopegally all MIG and flux cored power supplies are constant arc yeltage designs having a near flat open ended amperage response Hea gparticular voltage tapping selected. Increasing the wice feed motor speed will directly increase the are current ang the puonoorf rate will restore balance of the set voltage. Wit.cn 4s Preportional to amperage, so welding procedures may specify wafos. instead of amperage when meters are not fitred ov ace inaccurate. Deposition rate can be found from w.f.s. by Converting to equivalent amperage. Alternatively the rate of wire consumption (kg/hr) multiplied by its deposition ef ficiency | will give deposition rate. | RE FEED SPEFD AND WELDINGThe bar charts (Fig. 1) give the welding current (amperage) ar ppecific w.f.s. (metres per minute), each line ig specific to the diameter of the wire used and it's Composition, SUMMARY. The direct welding cost is the sum of the labour, shielding cost, consumables andTABLE 1 AMPERAGE a = = x = kglhy et ae TABLE 1.1 - C.1.G. and Murex Shielded Metal Arc Welding Electrodes. (Determined by Welding Trials.) : ieneet AS 1552 NOMINATED CURRENT DEPOSITION RATE PRODUCT SIZE EXAMPLE RANGE CONSTANTS MIN. AMPS | MAX AMPS, cl c2 Non-Iron 3.25 £4110 90 135 Powder Type | 4.0 £4113 135 180 0 0.0076 5.0 195 250 Low Iron 3.25 £4818 105 150 Powder Type] 4.0 E4814 145 200 33 0.0115 5.0 210 270 6.0 270 340 Medium Iron | 3.25 £4824 130 170 Powder Type £4828 185 235 49 0.0144 260 320 6.0 E4127 330 390ABLE 1.2 - C.1.6. and Murex Gas Metal Arc Welding an; qutsumabies. (Getermmned vy welding trials.) Autocraft LWI/CO, was considered ac being typical oF all MIG/CO2 cdnsumables. Stickout - asa AWS.AS.18-79 NOMINATED CURRENT DEPOSITION RATE PRODUCT SIZE CLASSIFI- RANGE CONSTANTS CATION MIN.AMPS MAX. AMPS cI c2 Autocraft 0.8 E70S~4 60 150 5 0.0113 twi/co, 0.9 90 200 40 0.0183 1.2 135 300 80 0.0210 1.6 330 435 140 0.0229 Goud ike :Consumables, + C21.G. and Murex Flux Cored Arc Welding (Determined by welding teinte ) erg AWS.A5.20-80 | NOMINATED CURRENT DEPOSITION RATE PRroouct “SIZE | CLASSIFI- RANGE CONSTANTS CATION MIN.AMPS | HAX.AMPS | CL ce Satincor 1.6 E70T-1 250 375 82 0.0257 1-11A 2.4 325 500 41 0.0166 Vertt-cor 1.200 Jeritea 150 275 72 0.0333 1-214 1.6 250 400 100 0.0219 Metal-cor 2| 1.6 E70T-6 300 450 181 0.0392 Supre-cor 1.6 | E70T-5 200 350 107 0.0179 5-11A 2.4 325 450 155 0.0271 Tensi-Cor 1,6 E110T5-K4 250 350 133 0.0316 110T 2.4 300 425 50 0.0152 Shield-cor 4 2.4 707-4 300 375 37 0.0191 eee —. | Muracore 1.6 E70T=1 300 450 140 0.0311 7 2.4 350 500 153 0.0234 Muracore 1.2 EV1T-1 150 275 72 0.0333 7 1.6 225 350 ql 0.0240TABLE 3 - PRODUCT EFFICIENCY FACTORS, C.1.G. and Murex products. (Oetermineg by welding triats.) ria PRODUCT j} SUE (mm) | process EFFICIENCY EFFICIENCY FACTOR Non Iron Powder 3.25-6.0 SHAW 59% 0.59 Types - E4111, | £4112, £4113 ete, ; { Low Iron Powder 3.25-6.0 SMAW 63% 0.63 types ~ E4814, £4818, £4818-A1 etc, Medium Iron 3,25-6.00 SMAW 60% 0.60 Powder types; £4824, £4127, £4828 Autocraft LW1/CO, 0.8-1.6 GMAW 95% 0.95 Satin-cor 1-118 1.6, 2.4 FCAW 82% 0.82 Verti-cor 1-214 1.2, 1.6 FCAW 824 0.82 Metal-cor 2 1.6 FCAW 95% 0.95 re-cor 5-11A 1.6, 2.4 FCAW 85% 0.85 Tenst-cor 110T 1.6, 204 FCAW 79% 0.79 Shield-cor 4 2.4 FCAW 79% 0.79 Muracore 71 1.6, 2.4 FCAW 82% 0.82 Muracore 71V 2%, L6 FCAW 80x 0.80% Autocraft SA1/ 2.4,3.2,4.0] saw Wire 100%. 1.00 Sutinare 4 4.8 Add flux:- Plus - fn Butt 90% 0.90 - in Fillet 65x 0.65 - uM-recirculated 0.40 40x.- Competitor Flux Cor. (Obtained from ed Arc Welding Consumables. published product literature.) Stickout - 25mm, eee ————____ = aan AWS AS. 20-80] NOMINATED CURRENT DEPOSITION RATE »RooucT SIZE | CLASSIFI. RANGE CONSTANTS CATION a MIN. AMPS c2 Flux-o-fil | 1.6 E70T-1 200 375 70 0.0211 LL Ni 2.0 300 445 Lay 0.0190 2.4 300 470 112 0.0173 Flux-o-fil | 1.6 E70T-5 200 390 85 0.0207 3 2.4 300 485 125 0.0180 Flux-o-fil | 1.6 ELLOT5-K4 200 390 85 0.0207 42 2.4 300 485 125 0.0180 Dual-shield| 1.6 €70T-1 200 375 104 0.0290 111 AC 2.4 350 | 550 175 0.0270 Oual-shield| 1.2 E71T-1 165 | 280 110 0.0343 7000 1.6 180 430 122 0.0303 Oual-shield T-75 2.4 E70T-5 300 450 61 0.0198 Gual-shield| 1.2 E110T 190 | 300 715 0.0205 TS 1,6 250 j 440 68 0.0216 Lincoln NR302 2.4 | E70T-6 435 565 205 0.0248 Lincoln 2.0 | €70T-6 160 300 55 0.0125 WR211 2.4 220 360 90 0.0152 Lincoln 1,7 E70T-G 110 295 85 0.0170 WR202 2.0 150 350 110 0.0190 Lincoln NR311 2.4 E70T-6 240 400 140 0.0290 Lincoln KS3M 2.4 EroT-4 250 110 0.02805 ~ C.1.G. and Murex Submerged Are Welding Consumables. (etermined ny welding trials.) AVTOCRAFT SAI/SATINARC 3 wos considered as being typical of all mild steel wire/agglomerated flag consumables, AWS.AS.17 NOMINATED CURRENT DEPOSITON RATE Proouct SIZE -80 RANGE CONSTANTS MIN.AMPS | MAX.AMPS | CL ce Autocraft SAL 2.4 F7AG-EL12 320 600 10 0.0174 wire/Satin-| 3.2 390 670 60 0.0175 arc 4 flux | 4.0 470 770 110 0.0180 4.8 550 950 172 0.0190TABLE 2 - DUTY CYCLE FACTORS The Duty Cycle Factor will vary depending on the type of work and the complexity of the job. The figures below are considered to be estimates which have been determined from past expertence. PROCESS PERCENTAGE DUTY CYCLE FACTOR Manual Arc (SMAW) 10-20% 0.10 - 0.20 Manual Arc (SMAW) Iron Powder 15-25% 0.15 - 0.25 Electrodes GMAW 20-35% 0.20 - 0.35 FCAW 20-35% 0.20-0,35 SAW 40-70% 0.40 - 0.70TABLE 3 (cont. ) COMPETITOR PRODUCTS (OBTAINED FROM LITERATURE, paopuct : SIZE (mm) pRocess EFFICIENCY EFFICIENCY FACTOR Flux-o-fil 11 N4 1,6,2.0,2.4] FcaW 80x 0.80 Flux-o-f 41 31 1.6, 2.4 FCAW 80% 0.80 Flux-o-fi1 42 1.6, 2.4 FCAW 80% 0.80 Dualshield 111Ac en 2.4 FCAW 854 0.85 Oualshield 7000 1.2, 1.6 FCAW 80% 0.80 Dual shield 1-75 2.4 FCAW : aor 0.80 Dualshteld T-115 1.2, 1.6 FCAW 75% 0.75 Lincoln nr302 2.4 FCAW 80% 0.80 Lincoln nr2ui 2.0,2.4 FCAW 15% 0.75 Lincotn nR2o2 1.7, 2.0 FCAW 78% 0.75 Lincoln NR3i1 2.4 FCAW Box 0.80 Lincoln Ns3m 2.4 FCAW 80% 0.80 —-TABLE 4 = CYLINDER CAPACITIES OF C.1.6 MUXIUKES. MELDING GASES AND GAS PRODUCT NAME CYLINDER ORDERING CAPACITY cove (AT 15°C & 100KPa) Welding grade (31 ka) Carbon Dioxide G 16.8 M (Code No. 080) Welding Grade G 8.0 M3 Argon E 4.0 4 (Code No. 061) Argoshield 40 6 7.0 43 (Code No. 068) Argoshield 50 G 7.0m3 (Code No. 060) Argoshield 81 G 7.4 M8 (Code No. 065) Argoshield 52 6 7.4 43 (Code No. 070)Figure 2 - Joint Area Calculated, 1. “Fillet Welds Area = a x b AMlow Ws of mitre area for reinforcemonits . 2. Graphical Method. Draw joint dimensions full size on millinetre graph paper. For a symetrical joint, the total joint area is the sum of the Areas multiplied by two. Root gouge area must be taken into consideration in a single side Preparation. Add 10$ of total area for reinforcement metal,Consider a set through nozzle 3. SEGENT MMOD. | | joint. | | Area = B+ C = a x b >’ a Area) = a x b Zi b+] i ale. where b = a Tan 25Higure 1. War Charts for MS vs Amperage. Determined by welding trials, Products - Stickout = 2Smm hit fee eB 8 7 botiatititwiititiiiiiviit fle fae Ltt 2 tim CAI 250 AMPS $00 mt em CAL 250) AMPS 450 a a oe HA 150 APS 300 1.0mm FCA = Metal Cored type. 250 AMPS 450 G,, and Murex Gas ing Products - Stickout = 10mm 2 i4 ot) F 8 2 ee oe oe a te Pde Eee Te le tai — 1.6mm MIG 200 ANP: 400 J— 1. 2mm NIG 100 AMPS 350 ane — 0.0m 100 AMPS 250 MIG 7 0.8m MG 75 NPS 175FI OE LOU TIGL ELECTRODE SIZE JOINTAREA ma? LOINTLENGTHM AMPERAGE CALCULATION OF WEIGHT OF REQUIRED METAL ane CALCULATION-OF DEPOSITION RATE a eg] - zs CALCULATION OF ARC TIME WEIGHT OF WELD : WEIGHTOF WELD = = DEPOSITION RATE wl I CALCULATION OF LABOURCOST LAGOURRATES SiR ; ARCTIME L x > = ourvevoieracton Lo! ELECTRODE PRICE Sik WEIGHT OF WELO x + EFFICIENCY FACTOR GAS PRICE SIME CALCULATION OF CONSUMABLE COST CALCULATION OF SHIELDING COST hr