25 Weld
Costs The ability
to weld at high speeds, with high current, and produce consistent defect free
welds usually makes
the submerged are process the least expensive automatic welding process one can
employ. Most bare
electrodes and fluxes are also relatively inexpensive with the combined costs
often lower per pound of deposited
metal than equivalent shielded metal-arc, or flux cored arc materials.
With the proper materials handling equipment
and shop flow facilities high operating factors from 50 to 90
percent can be achieved. Operator fatigue
is minimal since face shields, leather gloves and clothing, smoke
and fume irritants which limit productivity
with open arc processes are eliminated. The
high welding speed, economy of weld metal and power employed, low materials cost,
high manpower productivity
can make the submerged arc welding process up to 20 times less expensive than
manual welding
techniques. In
estimating actual costs, one must consider the following operating cost savings
to justify welding and fixturing
equipment investments. Since there is no stub or spatter loss, the electrode deposit
efficiency can be
considered 100 percent. Welding flux consumption is approximately 1lb. flux fused
per lb. electrode however,
handling losses will cause actual usage to vary from 1.4 to 2.5 lb. flux/lb. wire
depending on recovery
methods for unfused granular flux. With efficient vacuum recovery systems, the
lower 1.4 lb. flux/ lb.
wire usage rate can be achieved. Electrical
power requirements will vary from 1.0 to 2.0 Kw hr./lb. of electrode depending
on the specific power
source and associated fixture power requirements. The
following method of analysis can be followed by using actual costs, welding parameters,
and operating factors
expected: Continued
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