Lesson 9 - Estimating & Comparing Weld Metal Costs http://www.esabna.com/euweb/awtc/lesson9_8.

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Current
Lesson 1 Chapter
LESSON IX
The Basics of Arc Table of
Welding Contents
ELEC. DEPOSITION 2" 3" 4" 5"
LENGTH EFFICIENCY STUB STUB STUB STUB

60% 50.0% 45.0% 40.0% 35.0%

Lesson 2
Common Electric 65% 54.2% 48.7% 43.3% 37.9%

Arc Welding 12" 70% 58.3% 52.5% 46.6% 40.8%

Processes 75% 62.5% 56.2% 50.0% 43.7%
80% 66.6% 60.0% 53.3% 46.6%
STUB LOSS CORRECTION
60% 51.4% 47.1% 42.8% 38.5% Go To Test
TABLE FOR COATED
Lesson 3 65% 55.7% 51.1% 46.4% 41.8%
Covered Electrodes ELECTRODES
14" 70% 60.0% 55.0% 50.0% 45.0%
for Welding EFFICIENCY INCLUDING Print
75% 64.3% 58.9% 53.6% 48.2%
Mild Steels STUB LOSS
80% 68.5% 62.8% 57.1% 51.4%
FIGURE 5 60% 53.3% 50.0% 46.6% 43.3%

Lesson 4 65% 57.7% 54.2% 50.5% 46.9%

Glossary
Covered Electrodes 18" 70% 62.2% 58.3% 54.4% 50.5%
for Welding Low 75% 66.6% 62.5% 58.3% 54.2%
Alloy Steels 80% 71.1% 66.6% 62.2% 57.7%

9.2.6 Efficiency of Flux Cored Wires - Flux cored wires have a lower flux-to-metal ratio
Lesson 5 than coated electrodes, and thereby, a higher deposition efficiency. Stub loss need not be
Welding Filler Metals
for Stainless Steels considered since the wire is continuous. The gas shielded wires of the E70T-1 and E70T-2
types have efficiencies of 83%-88%. The gas shielded basic slag type (E70T-5) is 85%-90%
efficient with CO2 as the shielding gas, and the efficiency can reach 92% when a 75% argon, Turn Pages
Lesson 6 25% CO2 gas mixture is used. Use the efficiency figures in Figure 9 for your calculations if the
Carbon & Low Alloy
actual values are not known.
Steel Filler Metals -
GMAW,GTAW,SAW
9.2.6.1 The efficiency of the self-shielded types of flux cored wires has more variation
because of the large variety of available types that have been designed for specific applica- Search
Lesson 7
Flux Cored Arc tions. The high deposition general purpose type, such as E70T-4, is 81%-86%, depending on Chapter
Electrodes Carbon wire size and electrical stick-out. The chart in Figure 9 shows the optimum conditions for each (Faster
Low Alloy Steels Download)
wire size and may be used in your calculations.
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9.2.7 Efficiency of Solid Wires for GMAW - The efficiency of solid wires in GMAW is Document
Lesson 8 (Slower
very high and will vary with the shielding gas or gas mixture used. Using CO2 will produce the
Hardsurfacing Download)
Electrodes most spatter and the average efficiency will be about 93%. Using a 75% argon-25% CO2 gas
mixture will result in somewhat less spatter, and an efficiency of approximately 96% can be
expected. A 98% argon-2% oxygen mixture will produce even less spatter, and the average
Lesson 9
efficiency will be about 98%. Stub loss need not be considered since the wire is continuous.
Estimating &
Comparing Weld Figure 6 shows the average efficiencies you may use in your calculations if the actual effi-
Metal Costs ciency is not known.

Lesson 10
Reliability of Welding
Filler Metals

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