Costing of J oining Methods -

Arc Welding Costs

ver. 1
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
1
Overview Overview
Cost components
Estimation of costs Estimation of costs
Examples
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
2
Cost Components Cost Components
Materials
Labor Labor
Overhead
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
3
Materials Costs Materials Costs
Electrodes Electrodes
Some electrode sticks contain flux
Amount of electrode times electrode cost Amount of electrode times electrode cost
per unit weight gives electrode cost
Fluxes / Shielding gases Fluxes / Shielding gases
Quantity of flux and/or shielding gas
required times unit costs gives flux/gas required times unit costs gives flux/gas
cost
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
4
Material Costs Material Costs
Other consumables
may include cost of electricity, if not in may include cost of electricity, if not in
overhead
rags, files, blades, chisels. g , , ,
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
5
Labor Labor
Di t ti f ldi Direct time of welding
time to produce a length of weld
labor rate
multiplication gives labor cost per length
Set-up time, etc.
Personal time Personal time
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
6
Overhead Rate Overhead Rate
Usually a percentage of direct labor rate
Ranges from50 - 400% Ranges from 50 400%
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
7
Deposition Efficiency Deposition Efficiency
N t ll l t d i d it d ld Not all electrode is deposited as weld
lost as splatter, vaporization
stub ends left
Stick-electrode welding - 65%
Self-shielded, flux-cored welding - 82%
Arc welding with shielding gas - 92% Arc welding with shielding gas 92%
Submerged arc welding - 100%
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
8
Operator Efficiency Operator Efficiency
Welding time
Personal time
Set-up time
Electrode changing time g g
Slag chipping time (for subsequent passes)
poor weld quality increases time p q y
Time to beat weld to remove residual
stresses
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
9
Manual Operator Efficiency Manual Operator Efficiency
10 - 45%
65% is extreme of human achievement
Personal breaks
Set-up
Change position
Change electrodes g
De-slagging
Removing residual stresses
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
10
Removing residual stresses
Semi automatic Efficiency Semi-automatic Efficiency
25 - 60%
no need to change electrodes no need to change electrodes
wire used
higher currents speeds higher currents, speeds
some processes require no de-slagging
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
11
Automatic Efficiency Automatic Efficiency
Over 90%
if small set-up time, de-slagging time if small set up time, de slagging time
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
12
Cost Components Cost Components
Cost of electrode/length of weld
=(WE)(CE) (WE)(CE)
Cost of flux/length of weld
=(WF)(CF) =(WF)(CF)
Cost of gas/length of weld
(VG)(CG) =(VG)(CG)
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
13
Materials Cost/ Length (CM) Materials Cost/ Length (CM)
CM=(WE)(CE)+(WF)(CF)+(VG)(CG) CM (WE)(CE) (WF)(CF) (VG)(CG)
WE =weight of electrode WE = weight of electrode
CE = cost of electrode ($/wt)
WF weight of flux WF = weight of flux
CF = cost of flux ($/wt)
VG l f VG = volume of gas
CG = cost of gas ($/vol)
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
14
Labor Cost (CL) Labor Cost (CL)
CL = (t) (CR) / (OF)
t = time / length of weld
CR t f l b h d ($/ti ) CR = cost of labor + overhead ($/time)
OF = operating factor (efficiency)
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
15
Labor Cost (CL) Labor Cost (CL)
Alternatively Alternatively,
t = 1/S
S d f ld S = speed of weld
CL = (CR) / S (OF)
1 1 1
note
...
1 1
2 1
+ +
=
S S
n
S
n
S S S
t
1
...
1 1
2 1
+ + + =
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
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2 1
S S
Metal Deposition vs Labor Cost Metal Deposition vs. Labor Cost
1 1
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
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Labor cost $/ ft of weld
Estimated Cost of Consumables Estimated Cost of Consumables
gas = 25-45 ft
3
/hr, solid flux = wt of deposited metal, 1973 prices
Process Type of
Electrode
Electrode
Cost ($/lb)
Deposition
Efficiency
Cost of
Deposited
(%) Metal
$/lb $/ft
Shielded
metal arc
E7024 0.191 65 0.29 0.045
metal arc
Self-shielded,
flux-cored
E70T-G 0.315 82 0.38 0.059
Submerged EL12 0.199 +flux 100 0.34 0.053 Sub eged
arc
0. 99 u 00 0.3 0.053
Gas metal-arc E70S-3 0.243 +flux 92 0.31 0.048
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
18
Estimated Costs Estimated Costs
All about 5/ft.
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
19
Trade-off Example p
1/4 fillet weld, 3/32 E7024 electrode,
85 ft/hr, operating factor 30%, labor +
overhead $7/hr
CL = (CR)/S(OF)
CL=(7)/85(0 3) =$0 275/ft CL=(7)/85(0.3) = $0.275/ft
Can you increase efficiency somehow?
40% -> $0.206/ft
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
20
Comparative Costs Comparative Costs
Factor E8018 Electrode and
Manual Welding
9000C-1 Wire and
Semi-automatic
W ldi Welding
Labor and overhead rate (CL) $20/hr $20/hr
Deposition rate (D) 3.11 lb/hr 5 lb/hr
Operating factor (OF) 0.3 0.45 p g ( )
Cost of labor and overhead to
deposit weld
$21.43/lb of weld $8.88/lb of weld
Electrode cost (CE) $0.667/lb $1.019/lb
Depositionefficiency(DE) 068 078 Deposition efficiency (DE) 0.68 0.78
Cost of deposited metal $0.98/lb $1.31/lb
Shielding gas flow rate (VG) none 40 ft
3
/hr
Cost of shielding gas (CG) $0.72/lb dep. metal gg ( ) p
Cost of welding $22.41/lb dep. metal $10.91/lb dep. metal
Labor cost seriously offsets cheap stick cost
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
21
Costs of Various Processes
(relative for guidance)
P A d O ti L b d W ldC t Process Arc speed
(ft/hr)
Operating
Factor
Labor and
Overhead ($/hr)
Weld Cost
($/ft)
Shielded metal-
arc
85 0.3 7 0.274
Shielded metal-
arc
85 0.4 7 0.206
Gas metal-arc
i t ti
80 0.5 7 0.175
semi-automatic
Self-shielded
flux-cored, semi-
auto
100 0.5 7 0.140
Submerged arc
semi-auto
110 0.5 7 0.127
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
22
Weld Comparison for Mild Steel
b c a
d
f e
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
23
Weld Comparison Example p p
1/4 diameter, manual metal-arc electrode
with solid flux attached 320 A (a) with solid flux attached, 320 A (a)
Deposition rate 6.25 lb/arc-hr (b)
Weld required 0.6 lb of weld metal/ft (c)
Welding speed 2 in/min (5.75 arc-
minutes/ft) (d)
Operating factor 20%(e) Operating factor 20% (e)
Time is 28.75 minutes/ft, labor cost at
$8/hr is $3 83/ft of weld (f)
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
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$8/hr is $3.83/ft of weld (f)
Other Issues Other Issues
Calculations show what can happen, if
you have the correct equipment. y q p
Other costs
depreciation taxes etc depreciation, taxes, etc.
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
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Summary Summary
Costs of arc welding can be calculated
Calculations give you guidance on: Calculations give you guidance on:
process selection
operating condition targets operating condition targets
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
26
ME 6222: Manufacturing Processes and Systems
Prof. J .S. Colton GIT 2009
27