On 7 No.20A g 3/84 | a PUTING WEIGHT OF WELD METAL Designers and operating personnel alike frequently have to compute the weight of weld metal required on a particular job, as a matter of either costing or determining the amount of material to be ordered for a particular job. Some- times these computations must be based on the configuration of the joint. The normal procedure to follow in such a case is to compute the volume (in mn3) of weld metal required to fi11 the joint and convert this to kg by multiplying by 7.83 x 10-6kg per cubic mm, which is the weight per cubic mm of steel. To simplify these computations, the following tables, for weld metal in kilograms per linear metre have been developed and their use is illustrated in Example 1. On other jobs, actual procedures are already established and it is possible to compute the weight of weld metal deposited in the joint based on the welding Procedures used. One way to do this is to compute electrode melt-off rate in kilograms per minute and divide by travel speed in metres per minute. A very important additional use of these aids is that of developing procedures for non-standard joints. If any two of the following three variables are known, the third may be found, as illustrated in Example 3: (1) Welding Current (amperes), (2) Travel Speed (nm per minute) and (3) Weight of Weld Metal (kilograms per lineal metre). EXAMPLE 1 - Computing the Weight of Weld Metal Based on Joint Design Using the following tables computations based on joint design are easy. Essentially it is a matter of breaking the cross section of the area to be filled with weld metal into geometric areas. The contributions of the individual areas can be found in the tables. Totalling these gives the kilograms of weld metal per metre required by the joints. For examole, consider the following joint design: This joint can be broken into component areas A, 2, C and D. Referring to the following tables the contribution of each of these component areas to the total weight of weld metal required by the joint is simply picked off the tables as follows: "t" dimension is 3 mm, "d" dimension is 28 mn, Read from the chart (Table 8) 0.437 kg per metre.CAB NO. 208 - 2. aT Included angle is 14°, "a" dimension B. ¢ is 26; Read from the chart (Table D) al 0.647 kg per metre bed PAT "t" dimension is 12mm, "d" dimension Gs d is 26; Read from the chart (Table A) f4_| 2.435 kg per metre. "e" dimension is 6mm; D. BD Read from the chart (Table C) 0.441 kg per metre. Adding these, the total weight becomes 3.96kg of weld metal per metre of joint. EXAMPLE 2 - Computing the Weight of Weld Metal Based on Welding Procedures. hen the welding procedures for a particular job are known, it is a simple matter to determine the weight of weld metal that will be deposited per metre of joint through the use of deposition rate information. Table F covers submerged arc welding. Other data is available in literature and experimentally, Use Table F to obtain the melt off rate in kilograms per hour. Divide this value by the travel speed in metres per hour to get the amount of weld metal deposited per metre. For example, using a 3.2mm electrode at 600 amps results in a melt off rate of §-80 kilograms per hour. Divide this by the travel speed of 60 metres per hour (1000mm/min) to get 0.113 kilograms per metre of weld. EXAMPLE 3. - Adjusting Procedures to Provide the Required Amount of Weld Metal For some types of joints, there are no established welding procedures. When such is the case the normal method of developing procedures is to find an established Procedure for a similar joint and alter it slightly to acconmodate the desired joint. For example, consider the following joint; to be welded with submerged arc: There are no established procedures for this joint. Probably the closest is that for the following joint.CAB NO. 20A -3- 6 a 10 = Ks L—es —| Power: pct Anperes : 670 Volts: 29 Electrode Size: 4.0mm Travel Speed: 406mm/min, In adjusting this procedure to the new joint, it is reasonable to assume that the 670 amperes would be about right and, therefore, the simplest thing to do would be to slow down the welding speed enough to provide the amount of fill required. To do this, first determine the amount of weld metal required to fill the new joint in the manner outlined in Example 1. In this case, it is determined to be 0.642 kg per metre of joint. ’ Now at 670 amperes, DCt, on a 4.0nm diameter wire the melt-off rate is 7.81 kilograms per hour (from table by interpolation). Divide this by the 0.642 kilograms per metre to yield a travel speed of 12.17 metres per hour, or 203nm per minute, which is an estimate of the speed which should be used to provide adequate fill in the joint. With this much of the procedure fixed, it is a simple matter to adjust the voltage to provide the desired bead shape. Expressed mathematically: Travel Speed (mm/minute) = NeltcoFt Rete (ka¢hour) x 1000 fate. (i dour) x 1000 And, for the above example: Speed = F-Bt% 100 = 203 mn/minute. The relationship may also be expressed as: = Melt-off Rate (kg/hour) x 1000 Weld Metal/metre (ka) = “travel Speed (nm/nin) x 60 OR Melt-of f rate (kg/hour) = Travel Speed _(nm/iin) x Netal/metre(ka) x 60 /4A/S CAB NO. 208 TABLE A Page 4 re Y T Y d ZA |. d 1 3 5 6 8 10 12 3 023 .070 117 M1 187 -234 -281 5 -039 <7 +195 234 -312 +390 468 6 2047 141 234 +281 375 468 562 8 062 +187 312 375 1) +624 .749 10 .078 234 -390 468 624 -781 +937 12 094 +281 +468 562 =749 937 1.124 4 =109 +328 +546 +656 +874 1,093 1.311 16 2125 +375 +624 749, +999 1.249 1,499 18 141 422 -703 +843 1.124 1.405 1,686 20 -156 468 +781 -937 1.249 1.561 1.873 22 172 .515 859 1.030 1.374 1.717 2.061 24 187 562 +937 1.124 1.499 1.873 2,248 26 203 -609 1.015 1.218 1.624 2.029 2.435 28 219 +656 1.093 1.311 1.748 2,186 2.623 30 234 -703 a7. 1,405 1.873 2.342 2.810 32 -250 =749 1.249 1.499 1,998 2.498 2,997 34 265 -796 1.327 1,592 2.123 2.654 3.185 36 281 +843 1.405 1.686 2.248 2.810 3.372 38 297 -890 1.483 1.780 2.373 2.966 3.559 40 312 -937 1.561 1,873 2.498 3.122 3.747 42 +328 +984 1.639 1.967 2.623 3.278 3,934 44 -343 1,030 L7m7 2.061 2.748 3.435 4.121 46 359 1,077 1.795 2,154 2.872 3.591 4,309 48 375 1.124 1.873 2,248 2.997 3.747 4.496 50 390 1.17 1,951 2.342 3.122 3.903 4.683CAB NO. 20A -§- TABLE 8 eet cera t ¢ 1 2 3 4 5 6 3 2016 - - - - - 5 026 - - - - - 6 +031 2062 - - - - 8 2042 083 - - - = 10 052 £104 2156 208 - - 12 2062 2125 187 250 2312 - u 073 46 219 291 364 437 16 083 -167 +250 +333 416 500 18 094 -187 281 375 468 562 20 108 208 2312 416 +520 624 22 14 2229 -343 458 572 687 24 2125 250 2375 500 624 2749 25 +130 260 +390 520 650 781 26 £135 271 406 2541 676 812 28 2146 291 437 583 729 874 30 2156 312 468 628 781 937 32 167 -333 -500 666 833 999 34 “77 354 -531 708 885 1,062 36 187 375 562 .749 937 1,124 38 -198 £395 593 791 989 1.186 40 208 416 2624 8331.08 1,249 42 219 437 656 874 1,093 1.311 4 229 458 687 916+ 1.145 1,374 46 239 479 78 957 1.197 1.436 48 «250 500 749 -999 1.249 1.499 50 260 +520 781 1.041 1.301 1.561 TABLE C d “er 3.110 a 5.306 6 441 8 784 AG 10 1.225CAB NO. 208 TABLE D Page 6 | 10 6 wd 14 20 60 70 90 3 8.62 x 1079 +012 +041 +049 070 5 +024 +034 +113 +137 +195 6 034 +050 +162 +197 +281 8 +061 +088 +288 +350 499 10 +096 +138 +450 546 +780 12 +138 +198 +648 +786 1,123 4 +188 +270 -883 1,070 1.529 16 +245 352 1.153 1,398 1.997 18 +310 +446 1.459 1.770 2.527 20 +383 -550 1,801 2.185 3.120 22 464 666 2.180 2.643 3.775 24 +552 -792 2,594 3.146 4,493 26 +647 +930 3.044 3.692 5.273 28 751 1.078 3.531 4,262 6.115 30 862 1.238 4.053 4.915 7.020 32 +981 1,408 4.611 5.593 7.987 34 1.107 1.590 5.206 6.314 9.017 36 1.241 1,782 5.836 7.078 10.107 38 1,383 1,986 6.503 7,887 11.263 40 1.532 2.200 7.205 8.739 12,480 42 1.689 2.426 7.944 9.634 13,759 44 1.854 2,663 8,718 10.574 15.101 46 2,026 2.910 9.529 11.557 16.505 48 2.207 3,169 10.376 12.584 17.971 50 2.394 3.438 11.258 13.654 19,500 wTCAB NO. 208 TABLE E Page 7 Fb TD, The. g Flat Convex Concave 3 2043 2051 2049 5 18 +143 136 6 -170 206 +196 8 -302 +366 -348 10 M12 -571 2544 w 680 823 783 uM 926 1.120 1.066 16 1.209 1.463 1,392 18 1.530 1.851 1.762 20 1.889 2,286 2.175 22 2.286 2.166 2,632 24 2.720 3.291 3,132 26 3.192 3.863 3.675 28 3.702 4.480 4.263 30 4,250 5.143 4,893 32 4.836 5,851 5.568 34 5.459 6.606 6,285 36 6.120 7.406 7.046 38 6.819 8.251 7,851 40 7.556 9.143 8.699 42 8.330 10.080 9.591 44 9.143 11,063 10.526 46 9.993 12.091 11.505 48 10.881 13.165 12.527 50 11.806 14.285 13,593 NAB. Fillet sizes are nominal. Mass of weld metal in kg/metre has been calculated in each case on the basis of a 10% oversize weld. i.e. "6nm fillet" kg/metre has been calculated as for 6.6mm fillet. ‘gnm Fillet" kg/metre has been calculated as for 8.8mm fillet. and su on, -/8R.U.K. & Vine. 1+ Apri? any WELDING TECHNOLOGY BULLETIN WELDING COST ESTIMATION This Bulletin ts a supplement to the Welding Economics section of the Flux-Cor Folder, It is intended as an example of the principles used and also includes Deposition Data relevant to opposition products and other welding processes, INTRODUCTION, Weld cost estimates are fundamental to successful tendering, cost control and product selection, First it must be said that costing the Welding component is best done in hindsight when the facts are known, so production records and job observation are essential to accurate estimating. There are a multitude of costs which may be grouped (a) Providing materials. (b) Preparation, handling and jigging. (c) Preheating, welding and cleaning. (a) Inspection and post heat treatment. Costs associated with group (c) are highest aud most tabous intensive and perhaps the eastest to reduce. Welding Cost Estimation deals with the preheating, welding and cleaning costs Tepsutholes Let us consider the labour rate in $/hre as 11 the [abour involved in these operations averaged over the time st takes to complete all of them. The welding duty cycle then is the fraction of this time that is actually spent with the are alight depositing metal, phe, labour, fuel and quantity of consumables used directly influence the process and product chosen. It must be remembered Ehat expenditure on Group (b) items can significantly reduce Group (c) costs.The basic aim of this method of cost calculation is simplicity without loss of accuracy. The cost cyuations are written sv 4s to be used with a simple pucket calculator and as such ace written tn chain arithmetical form The costing sheet attached {s divided into two principle sections, Part 1 - The magnitude of the job. Part 2 = The direct cost components of the job. | PART 1 - CALCULATION OF THE MAGNITUDE OF THE voB. SRR GALCULATION OF THE MAGNITUDE OF THE JOB. Essentially it is necessary to calculate (a) the weight of weld metal; (b) the time the welder will take to deposit it. Lal THE WEIGHT OF WELO METAL REQUIRED. THE WEIGHT OF WELD METAL REQ CALCULATION OF WEIGHT OF REQUIRED METAL JOINT AREA ty oo Be a JOINTLENGTHM ! kg S6 = FBq(co | It is essential to express the weld dimensions tn the units used on the sheet, 1.e. cross section in mm (millimetres) leagth in m (metres), The factor 128 is steel weldmetal density expressed as 128 cc/Kg. Joint area (mm®) is the filled area of the assembled joint Configuration. Design, fit-up and jigging have an important effect on weld costs by minimising the required weldmetal. [ 3° ie elyOraw the joint dimensions fut) size on millimets yPaRH Paper ong add up the square millimetres. Alternatively sketch the Joint and divide into easily calculated geometrical shapes te. rectangles and triangles. Total up the areas and edd say 10% for calcola tote, hese estimates may be improved by exact falculation but the simple approach will give surticrect accuracy fo cover variations in actual fabrication. Nudtiply the area in mm? by the length in metres of the weld Ko area ativide by 128, to obtain the required wetghe te £8: (here Many different joints are required use a tyentat Joint to estimate comparitive costs. If the cost exercise is purely a comparison between Processes say, FCAW vs SMAW, fa cPbitary weight of weldmetal can be selected, for example 100 Kg. For the case of automatic vs. manual welded butt welds, greater Savings are achieved by using reduced joint sections allowed for a deep penetration product (refer AS.1554 PART 1 (Cl. 3.3.2)), where this can be demonstrated by macrosect ion, 1.2 CALCULATION OF DEPOSITION RATE. SALCULATION OF DEPOSITION RATE. 1 Current Ke/itr at 100% Duty Cycl 1 1 ! 1 ' I ' i (2 = tinel I ' Amperage cl The Deposition Curve for a typical Arc Process,Within the nominated limits of current range the curve is a straight line The dapos sonatauts Ci and Cé represents a Conservative case for C.1.G. Consumables C1 © The position on the current axis (intercept). C2 = The slope of the line. C2 = change in Kg/nr. = tang change in current, Finding of the deposition rate (y Kg/hr.) for a particular Current (x amps.) then becomes a matter subtracting Cl and multiplying by C2, CALCULATION OF DEPOSITION RATE AMPERAGE qe = kg/hr The current chosen may be obtained from a number of sources, (a) Optimum published current for a consumable. () Current required by the procedure, (c) The wire feed rate converted to a current, Table 1 in the Appendix lists the deposition rate constants (C1 and C2] for the current range preferred with cach consumable, Fig. 1 in the Appendix converts wire feed rate to welding current. 1.3 CALCULATION OF ARC TIME, CALCULATION OF ARC TIME, The weight of weld metal required to complete the joint divided by the deposition rate in kg/hr. produces the arc time to Poaplete the Job. This 1s the welding time at 100% duty cycle factor, CALCULATION OF ARC TIME WEIGHTOF WELD. z WEIGHTOF WELD = aa hr 7 oerosmonrare —— |_yPART 2 = CALCULATION OF DIRECT WELDING COSTS. Once the magnitude of the job has been determined the actual direct welding costs may be calculated, The direct welding cost is broken into three additive components, Labour Cost Consumable Cost Shfelding Cost, 2 LABOUR COST, The direct labour cost is the labour rate multiplied by arc time and divided by the duty cycle factor. Calculation of direct labour cost depends on satisfactory estimation oft= Labour hours required for preheating, welding and cleaning, Labour rate in $/hr. as an average of rates for all above work, Welding duty cycle factor is the fraction of all the above time spent with the arc actually running, CALCULATION OF LABOUR COST LABOUR RATES SHA =§ ARC TIMI x > ourvevcceracton L—__J : 2.1.1 LABOUR RATE, ree fiber. used for calculation will vary considerably from shop may be those, RUSPOSeS Of process comparison an arbitary figure may be chosen e.g. $20/hr. The cost of total labour is dramatically effected by a process choice that avoids preheat, deskills the job or eliminates Bpegiag and post cleaning.’ When skilled labour {s difticalt to find a low skill product and procedure is very cost effective.OUTY CYCLE Factor, pais is the percentage of time tne arc is actually on. This wit} raey, (pendant upon the type of work and tne Process being Sim Aes Se@i-automatic process provides ¢ higher duty cycle than S:MAAWW. where frequent stops must. be made. The duty cycle factor will also vary for the same process “dependant upon the type of work. It Can be used to allow for al} non welding operations associated with completion of a joint. time Nigh deposition rate consumable is used to reduce welding trae without also reducing preparation ana Cleaning time then there will be a reduction in duty cycle. Table 2 in the Appendix gives Suggested duty cycle ranges for various process. This is very mich an area where accurate estimation is dependant upon expertence and hindsight, 2.2 CALCULATION OF CONSUMABLE cosr, The actual consumable cost to Complete a joint is the product of dopeenable price in $/Kg. and weight. of weldmetal divided by the deposition efficiency factor, CALCULATION OF CONSUMABLE COST ELECTRODE PRICE six “CTRODE PRICE $ikg L, 7 : $ WEIGHT OF WELD EFFICIENCY FACTOR at Pee eee f Wl 2.2.1 ELECTRODE PRICE, SLECTRODE PRICE, The electrode price used will be the actual price paid by the customer and should account for such factors as freight and discounts. For comparison Purposes the list prices can be used. 2.2.2 EFFICIENCY FACTOR, ALEICIENCY FACTOR. The deposition efficiency factor 4s defined as the % weight of weldmetal from a given weight of consumable, The efficiency factory is an important and sometimes overlooked Consideration in comparison of actual consumable prices,