7 E.  Deposition Efficiency The deposition efficiency is the relationship of the electrode used to the amount of the weld metal deposited expressed in percent, or: DE =       Weight of Weld Metal Weight of Electrode Used. For instance, if it takes 4 lbs. of electrode to deposit 3 lbs. (1.4 kg) of weld metal, E = 3/4 = .75 or 75%. F.   Gas Flow Rate (Cubic Feet/Hour) For GMAW with solid wires use a shielding gas flow rate of 25 to 30 cubic feet per hour. For small diameter flux cored electrodes (1/16” or 1.6 mm diameter and under) use 35 cubic feet per hour. For large diameter flux cored electrodes (5/64 and over) use 40-45 cubic feet per hour. G.  Gas Cost Per Cubic Foot Gas cost per cubic foot will vary depending on the type of shielding gas being used and your location. 3.   Complete the calculations in the “Proposed Method” and “Present Method” columns and record the calculated costs in the blanks on the far right, (5) & (6) of each column. 4.   Add the calculated cost and record the sums at the bottom, (7) & (8) of each column. 5.   Subtract “Present Method” cost (6) from “Proposed Method” cost (5) for each of the sections titled “Labor & Overhead”, “Electrode”, and “Gas”.  Enter the differences in the blanks indicated at right (5 minus 6). Negative numbers should be enclosed in parenthesis “( )”. 6.   In the “Total Variable Cost/lb” section, subtract “Present Method” cost (8) from “Proposed Method” cost (7).  Enter the difference in the blank indicated as “Total”.  Negative numbers should be enclosed in parenthesis “( )”. A (negative) number in “Total” represents  the cost reduction you will realize as a dollar saving per pound of weld metal deposited. 7.   The bottom section of the form will be useful if you must buy new equipment to use the proposed product. That part of the form is self-explanatory with the exception of the “DEPOSITION FACTOR”. The deposition factor is simply the deposition rate multiplied by the operating factor and is already a part of the calculation as shown at (9) in the labor and overhead formula for the proposed method. Covered
Electrodes
Stainless
Steel
Products
Solid Wire
& Rod
Products
ESAB
TIG & MIG
Wires
Cored
Wire
Products
Submerged
Arc
Products
Hard-
surfacing
Products
Calculations
Filler Metals
ASTM
Steels
Conversion
Tables
Consumption  Electrode/Wire
Consumption
Weld Metal Cost
Worksheet
Weight/Foot
Weld Metal
Weight/Meter
Weld Metal     