Covered

Electrodes
E. Deposition Efficiency

The deposition efficiency is the relationship of the electrode used to the amount of the weld metal
Stainless deposited expressed in percent, or:
Steel
Products DE = Weight of Weld Metal
Weight of Electrode Used.
Solid Wire
& Rod For instance, if it takes 4 lbs. of electrode to deposit
Products 3 lbs. (1.4 kg) of weld metal, E = 3/4 = .75 or 75%.
F. Gas Flow Rate (Cubic Feet/Hour)
ESAB For GMAW with solid wires use a shielding gas flow rate of 25 to 30 cubic feet per hour. For small
TIG & MIG
Wires diameter flux cored electrodes (1/16” or 1.6 mm diameter and under) use 35 cubic feet per hour. For
large diameter flux cored electrodes (5/64 and over) use 40-45 cubic feet per hour.

Cored G. Gas Cost Per Cubic Foot

Wire
Gas cost per cubic foot will vary depending on the type of shielding gas being used and your location.
Products
3. Complete the calculations in the “Proposed Method” and “Present Method” columns and record the
Submerged calculated costs in the blanks on the far right, (5) & (6) of each column.
Arc 4. Add the calculated cost and record the sums at the bottom, (7) & (8) of each column.
Products
5. Subtract “Present Method” cost (6) from “Proposed Method” cost (5) for each of the sections titled “Labor
& Overhead”, “Electrode”, and “Gas”. Enter the differences in the blanks indicated at right (5 minus 6).
Hard-
surfacing Negative numbers should be enclosed in parenthesis “( )”.
Products Filler Metal
Consumption 6. In the “Total Variable Cost/lb” section, subtract “Present Method” cost (8) from “Proposed Method” cost
(7). Enter the difference in the blank indicated as “Total”. Negative numbers should be enclosed in
StubLoss
Correction parenthesis “( )”.
Calculations
Electrode/Wire A (negative) number in “Total” represents the cost reduction you will realize as a
Consumption dollar saving per pound of weld metal deposited.
Weld Metal Cost
Filler Metals Worksheet 7. The bottom section of the form will be useful if you must buy new equipment to use the proposed
ASTM product. That part of the form is self-explanatory with the exception of the “DEPOSITION FACTOR”. The
Steels Weight/Foot
Weld Metal deposition factor is simply the deposition rate multiplied by the operating factor and is already a part of
the calculation as shown at (9) in the labor and overhead formula for the proposed method.
Weight/Meter
Conversion Weld Metal
Tables 7