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How to calculate Total Labor & Material Cost per Pound of Deposited Weld Metal

Welding Cost Formula

A/C  +  FD  +  L / RG   =  Total labor and material cost per pound of deposited weld metal

 

A
F
C
D
L
R
G

=
=
=
=
=
=
=

Price per pound of electrode or wire
Price per pound of flux
Deposition efficiency (%)
Pounds of flux used per pound of metal deposited
Cost of labor and overhead
Deposition rate in pounds per hour
% Arc time (operating factor)

 

Example :        Manual Arc - 3/16 Postalloy 214 @200 amps
                        ( $8.00/lb) / .70  +  ($25.00/hr) / (3.75 x .35) = $30.66

                   GMAW - Postalloy 2898-SPL @ 200 amps
                          ($5.00) / .98  +  ($25.00/hr) / (8 x .60)  =  $11.95

Cost Formula Welding Variables

Typical Deposition rate in lbs./hr. for different welding procecces

Welding Current
Amperes (D.C.R.P.)

Stick Electrodes

Semi-Automatic

Submerged-Arc

110
125
150
175
200
225
275
325
375
425
    475   
 525
 1..8
2.0
2.6
3.0
3.7
4.2
7.0
9.0
-
- 
    -   
 -		 -
-
-
6
8
10
12
14
16
18
-
-		 -
3
4
4
6
8
10
12
14
17
20
24


Typical Deposition Efficiency

Typical Arc Time

Manual...................................65%
Submerged Arc......................95%
Open-Arc Flux-Cored..............90%
Open-Arc Metal Cored............96%
Gas Metal Arc.........................98%

Manual.....................................................30%
Submerged-Arc........................................65%
Semi-Automatic GMAW or FCAW.............60%