Metal Cost Worksheet Instructions To
help you quantify your specific cost of weld metal deposited, ESAB has developed
the weld metal cost worksheet.
Directions will assist you in calculating your specific cost to deposit weld metal
while comparing it
to alternative methods or product. 1. Indicate
the complete descriptions of the proposed and present products at (1) and (2).
2. Secure the following
information for the formulas (3), and write the data in the proper blanks in the
proposed method and present method columns
(4). A. Labor
and Overhead Actual
labor and overhead rate of your customer. If this figure is unknown, select a
reasonable rate for
your area. This figure will be the same in the proposed and present method columns.
B. Deposition Rate in Pounds
Per Hour The deposition
rate is the actual weight of weld metal which can be deposited in one hour at
a given welding
current at 100% operating factor. In other words, it is the amount of weld metal
which could be
deposited in one hour if the welder could weld for a full hour without stopping.
C. Operating Factor
Operating factor is the percentage
of a welders working day that is actually spent welding. It is the
arc time divided by the total hours
worked multiplied by 100 and expressed as a percentage.
A 30% (.30) operating
factor means that only 30% of the welders day is actually spent welding.
If the customers
operating factor is not known, assume a 30% operating factor for SMAW, and a 45%
operating factor for semi-automatic
GMAW and FCAW. For automatic GMAW and FCAW, an operating
factor of 60% to 80% may be assumed. D. Electrode
Cost Per Pound Select
the quantity price bracket in which the customer now purchases his filler metal.
If unknown, select
the price bracket you think applicable and use for both the present and proposed
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