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Estimation and Comparison of Welding Cost of MIG & MAG Process on Mild
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 Proceedings of the National Conference on “RECENT ADVANCES IN MANUFACTURING ENGINEERING & TECHNOLOGY”
January 10-11, 2011

Estimation and Comparison of Welding Cost of MIG & MAG Process on

Mild Steel
Sunil Kumar1 Sachchida Nand2
1 2
AP PG Student
Department of Mechanical Engineering
Sant Longowal Institute of Engineering & Technology
Longowal, Sangrur, – 148106
Punjab India
Email: sunil_thappa@yahoo.com

Abstract
In the present work welding cost estimation was done. Welding cost estimation was done for MIG &
MAG and the cost difference has been investigated by calculating for both the cases (MIG & MAG)
for welding the piece of MILD STEEL (contains carbon 0.15 to 0.3 %, silicon 0.2 to 0.5 %,
manganese, sulphur and phosphorous as impurities). The calculation was done by Parameter method
and cost difference found was approximately Rs. 20 calculated for the mild steel pieces (150*15*80)
mm having butt welding with the V-groove (45 Degree). By market survey it was observed that in a
small scale industry total length welded per day is approximately 100 meter. If MAG is used instead
of MIG for the process where the properties required are satisfactory (by MAG welding) than one can
make more profit. The present work was done to generate data for MIG & MAG process.
Keywords: MIG, MAG, Cost estimation, Parameter method

1. Introduction: - The analogue method: It is based on the

In the present scenario Welding-cost estimate is classification and the indexes of the
one of the most important tools for the economic products to manufacture by the enterprise
conduction of a welding enterprise and other according to morphs-dimensional criteria
production enterprise. It is almost incredible that and to quality. The new product cost is
in this epoch of global competition and of estimated by comparison with reference to
almost daily survival struggle with the color of the last newly indexed products.
the bottom line. The setting up of a reliable
system concerning the estimation of costs, takes
a considerable importance for the manufacturing
enterprises working on request. The
manufacturing cost is generally obtained by the
produce of a part manufacturing time and the
manufacturing time estimation methods namely.
- The analytic method: It allows evaluating
a product manufacturing time thanks to the
decomposition of an elementary
manufacturing operation set. We define, for
each operation, the necessary time from
which we can calculate the manufacturing
cost: “manufacturing time multiplied by the Fig-1 Model perposed for the welding cost
manufacturing hourly cost “. estimation
- The parameter method: which is based
on the utilization of mathematical relations The analytic method consists in describing and
founded on the information’s gathered by developing the whole of operations necessary
the enterprise so as to be able to determine for the production of the product, this method is
if there exist the correlations between the known for its accuracy and by its slowness as
different times and the manufacturing well. To replace the analytic approach, many
operations. enterprises move towards the analogue and the
parameter methods. These methods are
relatively rapid, it is because they are essentially

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 Proceedings of the National Conference on “RECENT ADVANCES IN MANUFACTURING ENGINEERING & TECHNOLOGY”
January 10-11, 2011

synthetic and function in total darkness. They 2.2. Preparation cost:

provide the product cost according to certain The cost of cutting to dimension each single
characteristics which limit the negotiating piece of metal, the job was properly accounted
transparency of marketing men. In this study for and summed to the total. Set up preparation,
further estimation was done as per parameter alignment and measuring of gaps and distances
methods. are recurring operations: the implementation of
wisely conceived fixtures and measuring aids.
2. Welding-cost estimate: Specimen Angle Machine Time Cost
Cost estimation of welding process was done by Prepara- Taken
estimating the cost of each steps involved in tion
welding. So total welding cost was sub divided. V- 450 Shaper 10mins Rs.
i.e. Total Welding Cost: Groove M/C each 70/-
1. Base metal cost Specimen 3-Small Grinding 15mins Rs.
2. Preparation cost 15mm Cutters Cutter each 90/-
3. Weld Labor cost Specimen 2-Small Grinding 8mins Rs.
4. Filler Metal cost 6mm Cutters Cutter each 60/-
5. Gases cost Table 2: - Cost estimation of preparation
6. Equipment cost Total Specimen Preparation Cost: Rs. 220/-
7. Energy cost
8. Overhead cost 2.3. Labor Welding-cost:
9. Inspecting cost Weld labor is usually accounted for as an hourly
10. Finishing cost rate, which will be different for different welders
depending on their experience, skill, ability,
2.1. Base metal cost: versatility etc. Operator or operating factor
This is the cost incurred for procuring (including describes the percentage of time that a welder
custom dues), transporting, insuring, and employs in actual welding. Operating factor
handling, storing, testing and bringing all the values commonly accepted in the welding
material in the proper sequence, quality and industry range from 30 to 50%. This is one of
quantity at the place of erection, ready to be the reasons most commonly reported for
prepared for welding. management push to switch. Good practice
No. Material Carbon Silicon Mangnese suggests striving for obtaining good quality at
(Thick) +Sulphur the first attempt, in order to minimize
1 Mild 0.15% 0.2% - As unnecessary operations like repair, rework and
Steel - 0.5% 0.5% impurities re-inspect, which increase the costs without
(15mm) providing any gain or advantage in the business.
2 Mild 0.15% 0.2% - As (Material Cutting + Cleaning + Machining) =
Steel - 0.5% 0.5% impurities Cost Included with Other Costs. It is necessary
(6mm) to estimate the time required for welding a
Table 1: - Composition of the weldment specific demand. Its helps in calculating labor
Base-Metal Cost: Rs 480/- charges.
Welding Time = (Weight/ft. of Weld x ft. of
Weld) ÷ (Deposition Rate x Operating Factor)

Welding Labor Cost: Rs 50/-

2.4. Filler metal cost:

Fig-2 Specifications of weldment
Working with the correct size of filler metal has
a direct influence upon the Welding-cost. A
smaller size of electrode permits to increase
current density, which may have influence upon
penetration. A larger size permits working with
higher current, with consequent higher volume
of metal deposited per unit time. Deposition
efficiency is defined as the ratio, expressed in

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 Proceedings of the National Conference on “RECENT ADVANCES IN MANUFACTURING ENGINEERING & TECHNOLOGY”
January 10-11, 2011

percentage, of the theoretical weight (volume (Or)

multiplied by density) of the joint material
needed per unit length, to the actual weight of
filler metal consumed per unit length. This can
be best calculated from raw data or assumed if
based on previous experience. If we know the
weight of filler metal necessary to weld one unit
of length (meter or foot) of that given joint and
if we know the number of unit lengths welded in
one hour, by multiplying the two we get the
weight of filler metal used per hour. This is
called the Weld Deposition Rate; by multiplying
this result by the cost of filler metal per unit
weight we get the Welding-cost of filler metal
Consume in an hour.
Electrode/Filler Metal Used:
AWS: SFA-5.18, ER-70S-6, Grade – S4.
0.8mm Diameter Bare Wire
Carbon Manganese Silicon Sulphur +
Phosphorus
0.06- 1.3-1.6 0.7-1.0 <0.050
0.14
Table 3:- Composition of electrode
Deposition Rate (lbs/hr) ÷ Burn-off Rate (lbs/hr)
= 0.33/0.36 = 91.66 % (15mm)
= 0.15/0.16 = 93.57 % (6mm)
Filler Metal Cost = Filler metal cost per kg /
Deposition efficiency
=4.48 kg /0.916 = Rs 4.10/-
=4.48 kg /0.935 = Rs 4.18/-
2.5. Gases cost:
This cost intervenes only when auxiliary gases
are actually used in the process. In this case the
cost of gas per hour (including welding and non-
welding time when flow is zero) is obtained by
the hourly consumption rate.
Gases Used:
- CO2.
- (98%) Argon + (2%) Oxygen Mixture.
CO2 Cylinder Cost (Large) = Rs. 725/-
Argon Cylinder Cost (Large) = Rs. 1250/-
Oxygen Cylinder (Large) = Rs. 925/-
Since the amount of gas used is too low. Thus,
Gas Cost: Gas cost is near about 2% of total cost
i.e. Rs. 15/- for MAG and Rs. 35/-

Diameter Ø 0.8 Ø 1.0 Ø 1.2 Ø1.6 2.6. Equipment Welding-cost:

Current 80- 120- 200- The easiest way to account for equipment is to
50-70
230 280 400 record the rental cost, if the equipment is indeed
Amps
Amps Amps Amps rented. Otherwise the Accounting department
Feed should come up with a cost per hour or per day
2.5-
Rate 2.5-10 3-10 3-8 for each of the main pieces of equipment,
12
(m/min) including purchasing cost, cost of capital,
Voltage 15-20 Volts 25-30 Volts depreciation, maintenance costs and spare parts
Range (6mm Plates) (15mm Plates) costs.
Table 4: - Specification of electrode Equipment Cost: Negligible due to low range
near about Rs. 3/-.
Current Selected:
 Specimen (15mm) = Final Wt. –Initial 2.7. Energy cost:
Wt. = (3.02 – 2.69) kg = 0.33 kg For electric equipment the Welding-cost
 Specimen (6mm) = Final Wt. –Initial estimate should be calculated by multiplying
Wt. = (1.57 – 1.42) kg = 0.15 kg  Voltage by Amperage and dividing by 1000 and
Wire Feed Rate Selected:  by the electric efficiency of the equipment, times
 8mm/min (Kept same for all thickness) the price per kW.hr (kilo Watt hour) time the
Length of Wire Used: operating factor (actual arc-on time per hour). In
 1.48m (15mm) 0.36kg case of a gasoline engine driven power
 0.95m (6mm) 0.16kg generator, the hourly energy cost would be that
Weight of Weld Metal: of the gasoline used up in an hour of normal
work. When using electrically heated furnaces or
 Specimen (15mm) = Final Wt. –Initial
other implements for preheating or post heating,
Wt. = (3.02 – 2.69) kg = 0.33 kg
the cost of energy used for heating should be
 Specimen (6mm) = Final Wt. –Initial
estimated and accounted for.
Wt. = (1.57 – 1.42) kg = 0.15 kg
Power/Energy Cost= (COST/kWh x VOLTS x
Deposition efficiency = Weight of Weld AMPS) / (1000 x DEPOSITION RATE)
Metal (kg) ÷ Weight of Electrode (kg) Used

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 Proceedings of the National Conference on “RECENT ADVANCES IN MANUFACTURING ENGINEERING & TECHNOLOGY”
January 10-11, 2011

Units Electricity Consumed= 4kwt Energy Electricity 2 Units

28/- 28/-
Cost : Rs. 28/- Consumed each
2.8. 2.8. Overhead cost:
Overhead Travelling,
Overhead costs include all expenditures that it 210/- 210/-
Charges Handling
is not practical to account for individually but
that when summed up amount to a considerable Total Cost 1030/- 1010/-
outlay. They include office costs, all indirect
personnel costs, taxes, insurance, transportation, Table 5: - Total cost estimated foe MIG and
advertising and sales, and also auxiliary MAG
consumables not specifically devoted to any The only difference in MIG and MAG is the
identified job. In practice it will usually be shielding gas used. Carbon Dioxide is cheaper
defined as a certain percentage of Labor costs (i. than argon and oxygen also thus it’s easy to find
e. 150%) but any rate may be valid although in urban Ares.
some effort should be exerted to attempt a
realistic figure. 3. Conclusion:
Travelling Charges + etc.: Rs. 210/- There is no mystery in Welding-cost estimate: it
is mainly a question of common sense. But it
2.9. Inspection cost: must be appreciated that correct accounting for
For demanding application inspection costs may total Welding-cost incurred in a welding
involve the employment of sophisticated operation is a preliminary requirement to the
techniques (Ultrasonic Testing and/or assessment of the best practices and a necessary
Radiographic Inspection) and of expert tool for the economic management of any
technicians to carry them out. Inspection costs welding enterprise.
depend mainly on quality requirements and will It is estimated from the recorded data that except
be generally accounted for whole projects. material cost, cost division gained is shown in
Inspection Cost: Nil fig-3.

2.10. Finishing cost:

A certain number of operations may be required
after all welding is completed. There may be
final cleaning and grinding, spatter removal,
post weld heat treatment cycles, painting,
assembling for erection or disassembling for
transportation and any other activity specified in
the purchase order. Finishing Cost: Nil

Welding Mig Mag

Quantity
Costs cost cost
Rs. Rs. Fig-3 Cost divison
Base metal
110 480 /- 480 /- The reasons for estimating welding costs are
cost
varied, but most often are to:
Preperation 5 cutters +
220 /- 220/-
cost 112mins
Weld Labor  Compare the economics of welding with
45 mins 50/- 50/- some other method of fabricating or
cost
manufacturing.
Filler Metal 1.4-1.5 m 4-5 /- 4-5 /-  Provide data needed for bidding a job.
 Establish information required in
Gas Cost ------ 35 /- 15/- making a decision between alternate
Equipment designs.
Cost
4 mins 3/- 3/-  Evaluate proposed changes in
procedures.

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 Proceedings of the National Conference on “RECENT ADVANCES IN MANUFACTURING ENGINEERING & TECHNOLOGY”
January 10-11, 2011

 Compare the economic advantages of [9] J.P. Ganjigattia, Dilip Kumar Pratihar, a,
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cluster-wise regression analyses for prediction of
In between MIG and MAG, as though cost bead geometry in MIG welding process” ,
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scale industries are using this process. This Dhanpat Rai & Sons.
study can help these industries to estimate cost [12]American Welding Society’s official
for welding of their work pieces as already bead website (www.aws.org).
geometry study has been done on this material [13] International Organization of Standards
[8]. website (www.iso.org).
[14] M. Suban, J. Tusek, 2001, Dependence of
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