©
COPYRIGHT 2000 THE ESAB GROUP, INC. LESSON
IX 9.7 OTHER
USEFUL FORMULAS The
information discussed below will assist you in making other useful calculations:
TOTAL POUNDS OF ELECTRODES REQUIRED
(REF. EXAMPLE 1) The
following information/variables must be determined prior to completing calculations:
(1)
Proposed Method Cost Calculation (2)
Present Method Cost Calculation Flux
Cored Arc Welding
Gas Metal
Arc Welding
E71T-1
.045 Dia. at 180 Amps
(3)
ER70S-3
.045 Dia. at 125 Amps
(4)
Actual
Labor & O/H Rate for your Customer
30.00
$
Actual
Labor & O/H Rate for your Customer
30.00$
Deposition
Rate in Pounds per Hour
4.9
Deposition
Rate in Pounds per Hour
2.8
Operating
Factor
45%
Operating
Factor
50%
Electrode
Cost per Pound
1.44
$
Electrode
Cost per Pound
0.66
$
Deposition
Efficiency
85%
Deposition
Efficiency
96%
Gas
Type
CO2
Gas
Type
75%
Ar/25% CO2
Gas
Flow Rate
35
Gas
Flow Rate
30
Gas
Cost per Cubic Foot
0.03
$
Gas
Cost per Cubic Foot
0.11
$
Equipment
Cost
-
$
Prepared
For:
NAME
INFO
Customer Name:
NAME
INFO Date:
(1)
Proposed Method Cost Calculation (2)
Present Method Cost Calculation Result
Formulas for Calculating
Flux
Cored Arc Welding Gas
Metal Arc Welding
(Cost
Reduction )
Cost per Pound
Deposited Weld Metal E71T-1
.045 Dia. at 180 Amps ER70S-3
.045 Dia. at 125 Amps Cost
Increase Labor&
=
Labor
& Overhead Cost /Hr
=
$30.00
=
$30.00
=
$13.605
$30.00
=
$30.00
=
$21.429
($7.823
) Overhead
Deposition
Rate
(lbs / hr)
X
Operating
Factor
4.9
X
0.45
=
2.205
2.8
X
0.5
=
1.4
Electrode
Electrode
Cost/lb =
1.44
=
1.694
0.66
=
0.688
$1.007
Deposition
Efficiency 0.85
0.96
Gas Type = CO2
Gas
Type = 75% Ar/25% CO2 Gas
Gas
Flow Rate (Cuft/hr) X
Gas Cost/Cu ft. =
3
5
X
0.03
=
1.05
=
0.214
3
0
X
0.11
=
3.3
=
1.179
($0.964
) Deposition Rate (lbs&/hr)
4.9
2.8
Sum
of the Above Total
Variable Cost/lb Deposited
Weld Metal =
$15.514
Total
Variable Cost/lb Deposited
Weld Metal =
$23.295
(
$7.781) T
otal Total Pounds
= Deposition
Efficiency
Wt/Ft of Weld x No. of Ft of Weld
Substituting the values from Example
1: .814 x 1,280
.630 =
1,631 lbs WELDING
TIME REQUIRED (REF. EXAMPLE 1) Welding
Time = Wt/Ft
of Weld x Ft of Weld Deposition
Rate x Operating Factor Substituting
the values in Example 1: .814
x 1,280
5.36 x .30 =
1,042 1.608
= 648 Hrs.
