19/05/2020 Handbook - Calculations

Covered
Electrodes

Weld Metal Cost Worksheet Instructions

Stainless
To help you quantify your specific cost of weld metal deposited, ESAB has developed the weld metal cost
Steel
Products worksheet. Directions will assist you in calculating your specific cost to deposit weld metal while comparing
it to alternative methods or product.

Solid Wire 1. Indicate the complete descriptions of the proposed and present products at (1) and (2).
& Rod
2. Secure the following information for the formulas (3), and write the data in the proper blanks in the
Products
proposed method and present method columns (4).
A. Labor and Overhead
ESAB
TIG & MIG Actual labor and overhead rate of your customer. If this figure is unknown, select a reasonable rate
Wires for your area. This figure will be the same in the proposed and present method columns.

B. Deposition Rate in Pounds Per Hour

Cored
Wire The deposition rate is the actual weight of weld metal which can be deposited in one hour at a given
Products welding current at 100% operating factor. In other words, it is the amount of weld metal which could
be deposited in one hour if the welder could weld for a full hour without stopping.
Submerged
C. Operating Factor
Arc
Products Operating factor is the percentage of a welder’s working day that is actually spent welding. It is the
arc time divided by the total hours worked multiplied by 100 and expressed as a percentage. A 30%
Hard- (.30) operating factor means that only 30% of the welder’s day is actually spent welding. If the
surfacing customer’s operating factor is not known, assume a 30% operating factor for SMAW, and a 45%
Products Filler Metal operating factor for semi-automatic GMAW and FCAW. For automatic GMAW and FCAW, an
Consumption
operating factor of 60% to 80% may be assumed.
StubLoss
Correction D. Electrode Cost Per Pound
Calculations
Electrode/Wire Select the quantity price bracket in which the customer now purchases his filler metal. If unknown,
Consumption
select the price bracket you think applicable and use for both the present and proposed calculations.
Weld Metal Cost
Filler Metals Worksheet
ASTM
Steels Weight/Foot
Weld Metal

Weight/Meter Continued on next page...

Conversion Weld Metal
Tables 6

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