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ESAB Weld Metal Cost Analysis

This document is a cost worksheet that compares the costs of using two different welding methods - a dual shield flux-cored wire and a solid wire electrode. It calculates the cost per pound of deposited weld metal for both methods, finding that the dual shield wire results in a $17.18/lb lower cost. It also estimates that it would take 37 welder hours of use to offset the $2,900 equipment cost difference through savings on weld metal costs alone.

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Smith Siva
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253 views1 page

ESAB Weld Metal Cost Analysis

This document is a cost worksheet that compares the costs of using two different welding methods - a dual shield flux-cored wire and a solid wire electrode. It calculates the cost per pound of deposited weld metal for both methods, finding that the dual shield wire results in a $17.18/lb lower cost. It also estimates that it would take 37 welder hours of use to offset the $2,900 equipment cost difference through savings on weld metal costs alone.

Uploaded by

Smith Siva
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Covered
Electrodes
ESAB Weld Metal Cost Worksheet
Stainless Prepared For: Customer Name Date:
Steel
Products (1) Proposed Method Cost Calculation (2) Present Method Cost Calculation Result
Formulas for Calculating Dual Shield 7100 Ultra (E71T-1) E7018 3/16" (4.8 mm) (Cost Reduction)
Cost per Pound Deposited Weld Metal 1/16"  (1.6 mm) @ 300 Amps @250 Amps Cost Increase
Solid Wire (3) (4) (5) (4) (6) (5-6)
& Rod Labor & Overhead
Products Labor & = Cost/Hr = $45.00 = $45.00 = $9.80 $45.00 = $45.00 = $27.78 ($17.98)
Overhead Deposition XOperating 10.2   X 0.45 = 4.59 5.4    X    0.3    = 1.62
Rate Factor
ESAB (3) (4) (9) (5) (4) (6) (5-6)
TIG & MIG Electrode Electrode Cost/lb = 1.78 = 2.05 0.85 = 1.33 0.72
Wires Deposition Efficiency 0.87 0.64
2" (50mm) stub
(3) (4) (5) (4) (6) (5-6)
Cored Gas Flow Rate (Cu ft/hr)
Gas = 40 X 0.02 = 0.8 = 0.08 0 X 0 = 0 = 0 0.08
X    Gas Cost/Cu ft.
Wire 10.2 5.4
Products Deposition Rate (lbs/hr)
(7) (8) (7-8)
Total Variable Cost/lb Total Variable Cost/lb
Sum of the Above = $11.93 = $29.11 ($17.18)
Submerged Deposited Weld Metal Deposited Weld Metal
Total
Arc
Products
Pounds of Weld Metal and Welder Man Hours Required to Amortize Equipment Cost
Equipment Cost
Power Supply Equipment Cost in Dollars Pounds of Weld Metal   ÷ Deposition Factor = Welder Man Hours
Hard- Wire Feeder Savings/lb Required to Required to
surfacing Gun & Accessories Amortize Cost Amortize Cost
Filler Metal $2,900 (9)
Products Total $2,900 $17.18 = 168.8 ÷ 4.59 = 37   Hours
Consumption

StubLoss
Correction
Calculations
Electrode/Wire
Consumption

Weld Metal Cost


Filler Metals Worksheet
ASTM
Steels Weight/Foot
Weld Metal

Weight/Meter
Conversion Weld Metal
Tables 8

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