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IX. Cost Considerations of The GTAW Process: Formulas To Figure Total Welding Cost

The document discusses key cost considerations for gas tungsten arc welding (GTAW) including: 1) Direct costs like filler wire, shielding gas, equipment, and labor; 2) Indirect costs like overhead and training personnel; and 3) Proper equipment costs which can range from thousands for manual to tens of thousands for automatic setups. Formulas are provided to calculate costs per foot of weld for labor, overhead, filler metal, gas, power, and total cost. Values in the formulas will vary between applications and companies.

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176 views1 page

IX. Cost Considerations of The GTAW Process: Formulas To Figure Total Welding Cost

The document discusses key cost considerations for gas tungsten arc welding (GTAW) including: 1) Direct costs like filler wire, shielding gas, equipment, and labor; 2) Indirect costs like overhead and training personnel; and 3) Proper equipment costs which can range from thousands for manual to tens of thousands for automatic setups. Formulas are provided to calculate costs per foot of weld for labor, overhead, filler metal, gas, power, and total cost. Values in the formulas will vary between applications and companies.

Uploaded by

vishnu300022
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
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IX.

Cost Considerations of A cost evaluation of a welding process should include:


1. Labor and overhead cost per foot of weld.
the GTAW Process 2. Filler wire cost per foot of weld.
It is important to take into consideration all the facts that 3. Gas cost per foot of weld.
relate to a welding situation when attempting to attach a cost 4. Power cost per foot of weld.
to a foot of weld. Not only do direct costs such as filler wire, Computing these figures on a chart or proposal will show the
shielding gas, equipment, and labor have a bearing, but indirect economics of a particular process.
costs such as overhead and training of personnel have an
affect as well. Standard formulas for cost estimating as presented in this
book (Figure 9.1) are a reasonable measure for computing
Training should be considered in the cost since GTAW is data for cost comparison.
generally considered a more advanced process and will
require time by the welder to familiarize with the technical and The formulas as presented have no “plug-in” numerical values.
manipulative aspects of the process. The values will vary with each application and each company.

The cost of proper equipment to efficiently accomplish the


job at hand is of great importance. Manual GTAW equipment
in a production setup can run into thousands of dollars. If
there are many repetitive welds, automatic equipment should
be considered, and those costs can run into the tens of
thousands of dollars.

Formulas to Figure Total Welding Cost

Welder Rate in $ Per Hour


1. Labor = __________________________________________ = Cost per ft.
Weld Travel Speed (IPM) x Duty Cycle x 60 min./hr.
12"/ft.

Overhead Rate
2. Overhead = __________________________________________ = Cost per ft.
Weld Travel Speed (IPM) x Duty Cycle x 60 min./hr.
12"/ft.

3. Filler Metal Cost Weight of Deposit x Filler Metal Cost


Foot of Weld Deposition Efficiency

Cost of Gas/cu. ft. x Flow Rate (cfh) = Cost per ft.


4. Gas = ________________________________
Weld Travel Speed (IPM) x 60 min./hr.
12"/ft.

Volts x amps x power cost/kw. hr.


5. Power = ______________________________________________________ = Cost per ft.
Weld Travel Speed (IPM) x Machine Efficiency x 60 min./hr. x 1000
12"/ft.

6. Total = Total of Above Applying Formulas x Total Length of Weld = Total Cost

60 min./hr.
*The factor 5 will appear in some of the formula examples: This was derived from the ratio of:
12"/ft.

Figure 9.1 Formulas for cost considerations.

68

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