Calculate Filler Material
and Labour Cost
Calculate the filler material Cost per meter for
the welding job given the supplied data , as
shown below
Parent Material : Carbon Steel
Welding Process : GMAW
Density of steel = 7.85 x 103 Kg/m3
12 mm fillet weld
Cost of filler material = $8.50/kg
Wire Dia = 1.2 mm
Deposition Efficiency = 90%
Total length = 1meter
Useful Equations :
Wire used = Weight of weld metal ÷Deposition efficiency
Total Cost = Cost per Kg x Actual weight of consumable
Weight of weld = Volume x Density
Volume of Weld Metal
• Convert mm into metres
• Area of the cross section x Length
Area :0.012 x 0.012 = .000144/2= 0.000072 m2
Volume : 0.000072 x 1 = 0.000072 m3
Volume of weld metal
0.000072 M3
Weight of Weld
• Volume X Density
Density of steel = 7.85 x 103 kg/m
• 0.000072 x7.85 x1000 = 0.5652 kg per /meter of weld metal
Weight of Weld Metal
0.5652 kg p/m
Actual Wire Used
• Weight of weld metal ÷ Deposition efficiency 90% GMAW
• 0.5652 ÷ 0.9 = 0.628 kg
Actual Wire used
0.628kg per /m
Total Cost of Consumables
• Actual weight of consumable x Cost per kg ($8.50 /kg)
• 0.628 x $8.50 = $5.34
Total Cost of consumables
$5.34 per /meter
How many meters of weld will a 15kg spool of wire complete?
Total Meters of weld = 15kg ÷ 0.626 = 24 meters
Labour Cost
Material : Carbon steel
Weld joint Type T joint
Welding Process :GMAW
Hourly labour rate= $50
Single pass fillet weld on
both sides of equal length
Wire Dia =1.2 mm
Operator Factor= 40%
Weld leg length : 8mm
Total length of weld :1000mm
Deposition Rate =4.1 kg/hr
Arc on Time
• Weld Metal Deposited ÷ Deposition rate (4.1kg/hr)
•
• 0.628kg ÷ 4.1x 60min = 9.20 mins
Arc on Time
9 min 20 seconds
Labour hours/Labour Cost
• Arc on time ÷ Operator Factor (40%)
• 9.20 ÷ 0.4 = 23 minutes
Labour Cost
Labour hours x Labour rate
23 ÷ 60 min x $50 = $19.17
Labour Cost
=$19.17
Total cost of Consumable and Labour
• Filler metal cost total = $8.01
• Labour cost = $19.17
• 8.01 +19.17 = 27.18
Total Cost of labour and filler metal cost to weld 1000mm fillet weld on
a T-joint =
$27.18