Weld costs

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Hi,I'm working in a company that is specitalized in weld services. I'm doing a stud that how much cost an weld for any type of weld.I do an excel sheet, that when i insert the information of the materials, from the manufacturer, deposition eficiency, eletrical intensity and the deposition ratio, it give me the price of weld by meter. What i need to know is how, is how can i calculate the deposition eficiency and the deposition ratio by the eletrical intensity.We know that the deposition eficiency increase at the same rate that eletrical intensity increase.Did you know how?Best regards
Reply:I don't see how you are going to calculate this when deposition efficiency does not go up in all cases, for all processes, with the increase of amperage.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:Deposition efficiency of stick welding actually seems to be lower at higher intensity for a given size electrode due to spatter loss.  See http://www.esabna.com/euweb/awtc/lesson9_6.htmSolid wire processes are efficient because there is no flux loss considered.  Efficiency in terms of deposition rates and welding speed favors process such as spray MIG and Submerged Arc welding, which do have relatively high current densities."USMCPOP" First-born son: KIA  Iraq 1/26/05Syncrowave 250 w/ Coolmate 3Dialarc 250, Idealarc 250SP-175 +Firepower TIG 160S (gave the TA 161 STL to the son)Lincwelder AC180C (1952)Victor & Smith O/A torchesMiller spot welder
Reply:Welcome.  This question ought to bring out the guys with the green eye-shades.  30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Originally Posted by storemanWelcome.  This question ought to bring out the guys with the green eye-shades.
Reply:Dick,You need to get some sun.  I know we haven't had much lately, but grab it when you can.Jerry30+ yrs Army Infantry & Field Artillery, 25 yrs agoMiller 350LX Tig Runner TA 210, spool gunLincoln 250/250 IdealArcESAB PCM 500i PlasmaKazoo 30"  vert BSKazoo 9x16 horiz BSClausing 12x24 lathe20T Air Press
Reply:Get a copy of the Procedure Handbook of Arc Welding put out by Lincoln. It's pretty reasonable if you buy it direct from Lincoln. There is a section in it on determining welding cost written by Omar Blodgett who is the authority on this subject. Be warned you better have a masters degree in advanced mathematics!
Reply:So, how can i determinate the costs of a weld... The only way is weight the material and laboratory experience.
Reply:Originally Posted by João AreiasSo, how can i determinate the costs of a weld... The only way is weight the material and laboratory experience.
Reply:ESAB has a slick mini-YELLOW book a la MN Dave's comment.  No need to breakout a slide rule, microscope, stopwatch and calculator to determine deposition rates for any arc process.  Humans already assembled these tech refs."Discovery is to see what everybody else has seen, and to think what nobody else has thought" - Albert Szent-Gyorgyi
Reply:The procedure handbook has the formulae that you need.  In the end there is something called " operating factor".   People spend too much time figuring how much it cost to weld but not how much time is spent setting up to weld, moving, cleaning, painting, loading for shipping etc.  Some operations have a factor as low as five to one.  Only one fifth of the shop time is spent actually welding.  Number crunchers and welding salesmen rave about saving ten percent welding time but forget it took two hours to get the damn thing cleaned and several more to get it to the deck of the truck.   Years ago I was told by one estimator that had worked for a very large structural steel operation that 75 % of their time was spent on handling.
Reply:Yes, the procedure handbook goes into great detail. I think Lincoln may even have a more detailed book on welding costs. Deposition efficiency is only part of it.