Legal Statement Year 2006 release Copyright © 2002 Mark F. Mruczek
Terms This software was developed by Mark F. Mruczek If you use this product you agree to the following terms and conditions: 1 The user uses this software at their own risk. 2 This notice must be included with all copies made. 3 This product is used "as is" without warrantees or liability. It is your responsibility to know how to use this software. Any job/weldment quoted with this software is the users responsibility. Mruczek's Welding Engineering does not guarantee the accuracy of this product. 4 All risk associated with this products use is assumed by the user. 5 All cost calculated with this spreadsheet are for welding only. It does not take into consideration machining cost, material cost (other than welding material)
Changes To Spreadsheet If you make any changes to this spreadsheet you are responsible for any and all changes that you make.
Comments If you have comments, corrections or questions about this product send an email to
[email protected]. I will try to answer all e-mails in a timely manner.
[email protected]
Verification This program was verified the following ways 1 Hand calculations 2 Comparison with other commercial software and publications Although every effort was made to make this software as accurate and easy to understand as possible, there is no way to guarantee it's accuracy. There are assumptions that must be made concerning welder and process efficiency. Process efficiency is built into the program and the information was obtained from numerous publications. Welder efficiency is supplied by the user. This is one of the most basic factors in the cost calculations and must be determined as accurately as possible in order to make sound evaluations of welding cost.
Welder Efficiency Welder Efficiency - Welder Efficiency is the percentage of a welder’s working day that is actually spent welding. A 45% (.45) operating factor means that only 45% of the welder’s day is actually spent welding (4.4 hrs). The balance of time is spent installing a new electrode or wire, cleaning slag, positioning the weldment, cleaning spatter from the welding gun, preparing the joint, moving parts, coffee break etc. If the actual operating factor is not known, the following averages can be used. 30% may be used with the shielded metal arc welding process(SMAW) 50% may be used with the Gas metal arc welding process (GMAW) 45% may be used with the FluxCored Arc Welding process (FCAW) 45%-50% may be used with the Submerged Arc Welding process (SAW) 50% may be used with any automatic Welding process
Labor and Overhead Rates Labor and overhead are considered jointly in all calculations in this spreadsheet. Labor is the welder’s hourly pay rate which includes their wages and benefits. Overhead includes allocated portions of plant operating and maintenance costs.
Weld shops in manufacturing plants normally have established labor and overhead rates for each department. Labor and overhead rates can vary greatly from plant to plant, and also with location.
Weld Joint Drawings All weld joint drawings were produced usign Arc Works Software developed and distributed by Lincoln Electric Co. Copyright © 1998 Lincoln Electric Company
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DETERMINING WELDING COST MAIN MENU Please Select The Type of Weld Joint You Wish To Evaluate by Pointing to and Clicking on The Appropriate Picture Below
FILLET WELD
Double Bevel
Compound Single-Bevel
SINGLE - V GROOVE
Single-U
Double-U
DOUBLE-V GROOVE
Single-J
SINGLE BEVEL
Double-J
DETERMINING WELDING COST FOR A FILLET WELD Mark Mruczek Senior Welding Engineer Mruczek Welding Engineering
Project: Company: NREC Subject: Welding Cost & Time Welding process(es) Used: GMAW 1/4 fillet weld used for all welding Please Choose Units before entering data below
Leg Size (in) Filler material Process Gas Used
HSLA-80 Plate ER101TM ESAB
Process 1 0.250 in 0 Carbon Steel
Date: Page: ●
English Units
Leg Size (in) Filler material Process Gas Used
90Ar-10Co2
250 30 460 0.045 20000 11.0 30
01/16/06 1 of 2
Choose Units For This Sh...
0 GMAW (98Ar-2O2)
Amps Volts Wire Feed (in/min) Electrode Diam. (in) Total Length of Weld (ft) Travel Speed (in/min) Gas Flow Rate (ft^3/hr) Welder Efficiency Cost Electrode ($/lb) Labor/Overhead Rate Cost of Gas Gas Cylinder Size (ft^3) Power Cost Cost of Flux ($/lb)
Base Material: Product Form: Filler Material Trade Name:
A V in/min in ft in/min ft^3/hr
Amps Volts Wire Feed (in/min) Electrode Diam. (in) Total Length of Weld (ft) Travel Speed (in/min) Gas Flow Rate (ft^3/hr) Welder Efficiency
35%
Metric Units
Process 2 0.25 in 0 Carbon Steel 0 GMAW (98Ar-2O2) 90Ar-10Co2
250 30 460 0.045 20000 11.0 30
A V in/min in ft in/min ft^3/hr
35%
2.55 $/lb 2.55 $/lb Cost Electrode ($/lb) 25.00 $/hr 25.00 $/hr Labor/Overhead Rate 40.00 $/bottle 40.00 $/bottle Cost of Gas 330 ft^3 330.00 ft^3 Gas Cylinder Size (ft^3) 0.20 $/kwh 0.20 $/kwh Power Cost - $/lb - $/lb Cost of Flux ($/lb) Leg Size- The leg size shown above is what is required. For cost calculations 10% is added to the size shown. This is consistant with normal shop practices. In other words welders will typically produce a weld that is 10% larger than what is required. Fillet welds are assumed to be convex rather than flat for cost calculations (See Drawings to the right. Units = Last
1 1
Scroll Down To See Results
Flat
Convex
WELDING COST OUTPUT FOR A FILLET WELD OUTPUT FOR GMAW (98Ar-2O2) Amount of filler metal needed #VALUE! Number of passes per joint ~ #VALUE! Size of fillet weld** 0.248 Amount of shielding gas used #VALUE! Number of Gas Bottles Required #VALUE! Actual welding time #VALUE! Labor Cost #VALUE! Welding Electrode Cost #VALUE! Gas Cost #VALUE! Flux Cost $ Power Cost #VALUE! Initial Cost #VALUE! Final Cost #VALUE! Total cost per ft of weld #VALUE! Filler cost per ft of weld #VALUE! Flux cost per ft of weld Gas cost per ft of weld #VALUE! Labor cost per ft of weld #VALUE!
lbs in ft^3
Labor Cos t Welding Electrode Cos t Gas Cost Flux Cos t Power Cost
hr
$/ft $/ft $/ft $/ft $/ft
** Size of the fillet weld is based on heat input. This information can be used to adjust your amps & volts to achieve the leg size you entered in Cell B10 OUTPUT FOR GMAW (98Ar-2O2) Labor Cost Amount of filler metal needed #VALUE! lbs Welding Electrode Cost Number of passes per joint ~ #VALUE! Gas Cost Size of fillet weld** 0.248 in Flux Cost Amount of shielding gas #VALUE! ft^3 Pow er Cost Number of Gas Bottles Required #VALUE! Actual welding time #VALUE! hr Labor Cost #VALUE! Welding Electrode Cost #VALUE! Gas Cost #VALUE! Flux Cost $ Power Cost #VALUE! Initial Cost #VALUE! Final Cost #VALUE! Total cost per ft of weld #VALUE! $/ft Filler cost per ft of weld #VALUE! $/ft Flux cost per ft of weld - $/ft Gas cost per ft of weld #VALUE! $/ft Labor cost per ft of weld #VALUE! $/ft
#VALUE! Provides A
#VALUE!
Savings Relative To The
#VALUE!
Weld Cost CalcXL Written By: Mark F. Mruczek Copyright © 2002 Mark F. Mruczek
Updates since inception Date Change 16-May-02 Added Update Sheet Check Spelling Checked Against Sample Calculations 5-Feb-03 Added Compound Single Bevel Joint to the spreadsheet Moved all calculations to a separate page 8-Jul-03 Added Double-V, and Double Bevel joint to the spreadsheet Sample Values Entered 10-Oct-03 Added Units page Added units conversion VB code to each sheet 17-Jan-04 Added Single-U, Single-J, and Double-J Joints to the spreadsheet Updated all weld joint drawing using Arc Works drawing software From the Lincoln Electric company Updated Tables page to add more base metals, gases and welder efficiencies 27-Apr-04 Corrected errors in cost calculations Protected Spreadsheet 9-Aug-05 Added Deposition rate page to the spreadsheet Corrected errors in unit conversion calculations in VB code Updated Weld Joint Drawings Sample Calcs Ran-Verification Complete Added Notes to Fillet weld page and fillet weld drawing showing flat and convex beads 12//14/2005 Changed Name from Weld Cost Rev 3 to Weld Cost CalcXL 30-Jan-05 Filed for Copyright
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