Note: MIG photo untouched and no weld cleaning except brushing was provided. The best way to measure weld shop production efficiency is to ignore the costs incurred from the front and corporate offices, and simply review the weld deposition and quality that the typical welder on the weld shop floor daily produces. mm/sec x 2.362 = ipm Ledaren har resistans enligt IEC 60228 klass 5. the 500 welded parts, the robot requires 275 Divide by 512 ipm = one pound. Fracture Toughness, Metric Meganewton meter MN.m-3/2 cu/in x 0.00057870 = cuft For example in evaluating the Weld Efficiency in any weld shop all the "professional" weld decision makers should be aware of; [] the MIG weld transfer modes and their wire feed ranges that are availalble, A 1/4 fillet requires 0.11 lbs of weld wire per foot of weld. OFTEN HAVE IN COMMON? [1] How much weld wire required? IT'S BEEN MY EXPERIENCE AT THE NORTH AMERICAN SHIP YARDS THAT I WHEN MANAGERS HAVE PROCESS CONTROL - BEST PRACTICE EXPERTISE,IT'S EASY TO GENERATE MULTI-MILLION DOLLAR COST SAVINGS PER-SHIP: IT'S BEEN MY EXPERIENCE AT THE NORTH AMERICAN SHIP YARDS THAT I WAS INVOLVED WITH, TO FIND EXTENSIVE EXPERTISE WITH THE SMAW (STICK) PROCESS, WHILE MIG AND FLUX CORED WELD PROCESS CONTROL AND BEST WELD PRACTICE EXPERTISE WAS USUALLY IN SHORT SUPPLY WITH THE PERSONNEL THAT WERE RESPONSIBLE FOR THE WELDS. Weld wire cost per-part is 12.5 cents. Of course from a weld productivity perspective, the two gun weld procedure utilized, enabled the single operator to deposit > 26 lbs/hr. 60 minutes. Don't bother e-mailing me their confused replies. [] the most efficient MIG or FCA weld consumable size that should be used, for the power industry with WSI and Ed's new, "thinner" For 300 welders in a North American facility, that 40 hours training with labor and associated training costs would be approx. therefore the welding on the 500 trailers requires 550 man hours. WIRE 0.030 area = 0.00071 in/sq 2007: Welding Services (WSI now Aquilex) is the largest power industry contractor in North America. A 1" (25mm fillet requires 1.80 lbs of weld wire per foot of weld. THE MIG WELD GAS COSTS: The 80% argon - 20% CO2 cylinder mix cost $40.00 per-cylinder. Note; some companies when trying to evaluate welding costs, like to add the total white collar overhead including the kitchen sink and the coffee machines on the backs of the blue collar labor costs. [4] The total weld consumables costs per trailer. ft x 304.8 = mm The primary influence on robot weld efficiency is the required robot �arc on time� a time regulated by the wire feed rate attained. liters/min x 2.119 = cuft/hr. TRAILER COSTS WITH WELDS MADE BY A ROBOT. cuft/hr x 0.4719 = liters/min WSI applied for the US Patent during 2006 and the patent was approved in 2009. 0.052 (1.6 mm) MIG Wire. WIRE 0.035 area = 0.00096 in/sq IN WHICH THE WELD ALUMINUM HOW MANY POUNDS OF MIG WIRE REQUIRED? WITH A PROCESS IN WHICH THE ONLY CONSTANT IS THE WIRE FEED RATE, it's unfortunate that some Japanese robot programs provide "amps" but do not provide the robot wire feed rates used. 60 minutes. It's easy with so many overhead variables to make weld costs a very complex subject and therefore shy away from the subject. The number one controlling factor of setting optimum (consistent weld fusion) quality MIG welds for any weld weld transfer mode is to select the correct size weld wire (as discussed in my training resources and understand where you set the MIG wire feed setting. Aluminum 1/8 3.2 mm fillet = 0.092 lb/ft 0.03 kg/m, Aluminum 3/16 4.8 mm fillet = 0.026 lb/ft 0.04 kg/m, Aluminum 1/4 6.4 mm fillet = 0.05 lb/ft 0.07 kg/m, Aluminum 3/8 9.5 mm fillet = 0.06 lb/ft 0.09 kg/m, Aluminum butt weld 13 mm plate 60 degree single V = 0.3 lb/ft 0.43kg/m, Aluminum butt weld 18 mm plate 60 degree single V = 0.4 lb/ft 0.66kg/m, Aluminum butt weld 25 mm plate 60 degree single V = 0.82 LB/FT 1.2kg/m, Aluminum butt weld 38 mm plate 60 degree single V 1.7 lb/ft 2.6 kg/m, Aluminum butt weld 50 mm plate 60 degre single V 2.8 lb/ft 4.2 kg/m. Old school 3×9 or more and more popular 2×10 or perhaps the newest addition by SRAM XX1 1×11, (its enough to make a grown man cry). ecraig@weldreality.com. 압력관련 기준서를 들여다 보면 어떤 것은 N/mm2으로 표기되고 어떤 것은 kgf , 또 다른 자료에서는 MPa 등등 각각 다른 단위를 사용하여 표기한 것을 종종 볼 수 있다. Manual MIG weld speed 10 ipm. A WELD SHOP SUPERVISOR THE COST OF A MIG WELD AND THEY WILL When a manufacturing company invests in costly robots and fixtures, the robot purchase is in most instances intended to reduce the costs of manual weld production. gal/hr x 0.13368 = cuft/hr single clad weld passes and unique The manual labor costs for the same parts was $13.750.00. One wire feed turn is 70 ipm = approx 8 lb/hr. [] the weld Deposition Potential for the three most common fillet weld sizes utilized. 8 - 9 feet of weld will be delivered for that one pound of MIG weld wire. 0.062 (1.6 mm) MIG Wire. THE MANUAL MIG WELD LABOR COSTS: The average, 2015 hourly "welder's wage" in the USA is a sad $13 an hour, with benefits the hourly average wage would be approx. WIRE 0.8 mm area = 0.00458 cm/sq You know where to find this training resource. [5] The total weld only costs per / trailer. SIMPLIFY ROBOT WELD COSTS. 1 watt = 1 joule/sec 420 ipm = 12 lb/hr. 60 minutes. If you work in a weld shop in which weld personnel "play around" with their weld controls, how can you considers your organization to be professional when the welds are being produced by At least four parts an hour produced. With the increased arc on time and deposition, the robot deposits approx. In contrast, the last time I sat down with Lincoln or was it that Hobart rep? I would order 2310 pounds of MIG wire for the trailer project. Jag utgår från att du menar en kocentrisk skyddsledare typ ekkj eller fkkj. kan have intervaller 17-20, 20-24, 00-02, 02-06. HOW THE BAD NEWS: [b] technical advice is derived from salesmen, [b] OPTIMUM WELD QUALITY POTENTIAL: To consistently optimize weld quality, the weld decision maker must without getting advice from a salesman, fully understand the process, the weld mode, parameters, techniques and consumable requirements necessary. Visit the Clad weld section for more info. For the welders who took the eight 8 hour training, program the simple clock method enabled those individuals to have the ability to instantly set optimum parameters for both the consumables and the weld joint variables which in the yard were many. ... Raccordement type.....2 cosses electriques / cable 16 mm2. To show the management what an important missing link was in their yard, I provided a fundamental written process control weld test for all those involved including supervisors and QA personnel. In the following example we are MIG welding 24 parts an hour. Det har gett specialstal till oss och, mina vanner, Weldox ar idag SSAB:s storsta exportvara pa … 2 lb/hr. How many man-hours are required for the 500 trailers? cal/g x 4.1868 = kj/kg, Metric and When are you going to get a grip of weld costs? cm/sec x 1.9685 = ft/min Impact Strength, Metric = Joules = J The structural and engineering manager who should know this stuff, wants a quick quote on the following. The welds were in accordance with the ABS welder qualification requirements and with the information from the yard's weld procedures. To effectively manage a weld shop and maximize the daily robot weld quality and productivity, management, supervisors and engineers must provide their employees with a weld process control training program that provides; [a] MAXIMUM WELD PRODUCTIVITY POTENTIAL WITH LOWEST WELD COSTS: To minimize weld costs, those that make the weld decisions must understand the weld process fundamentals that focus on the application's weld deposition rate potential for the part thickness, the weld size, the wire size and weld transfer mode utilized. A 1/4 (6mm) fillet requires approx. The ABS welder qualification test also had little in common with the weld requirements and weld application variables which are typically found in any ship yard. Electrode Force, Metric Newton = N MN.m-3/2 x 0.910 = ksi/in �, Metric and 9 lb/hr (4.5kg/hr). That's 0.1 x 40 feet or 4.4 lbs of filler metal required per trailer. mig/mag用ソリッドワイヤー(軟鋼用) スター電器製造(suzukid) ￥2,490 ... 軟鋼・490n/mm2 ... ヒデ ファクトリー 様 [2020-05-29] This process subject is part of the fundamental weld process expertise that should be common knowledge in all plants that MIG and flux cored weld. To attain the minimum Chrome requirements the pulsed MIG weld procedures had to ensure the weld dilution was less than 8%. Divide by 512 ipm = one pound. WIRE 1mm area = 0.006193 cm/sq Udstyr til solceller og solcelleanlæg - skarpe priser, og hurtig levering. programs, it will take you 10 to 15 hours to learn what you need. 4 pounds per/hr. USING MY UNIQUE, SIMPLE WELD CLOCK CONTROL METHOD, WELD PROCESS CONTROLS IS MADE EASY. FEW WILL BE ABLE TO TELL YOU THE COST OF A 1/4 FILLET WELD THREE FEET IN LENGTH, BUT MANY IN THE FRONT ODDICE WILL TELL YOU 60 minutes. The 12 o'clock wire feed position with the 0.045 (1.2 mm) wire would deliver approx. This carbon steel E70S-6 MIG wire cost $1 per- lb. [C] WELD PROCESS CONTROLS: Once any production weld is established, that weld needs to be managed through the implementation of weld process controls. The 25% an hour increase in weld deposition allows 25% more parts per-hour. In an hour four parts produced so gas cost for the part is $0.25 cents. but also reduced the amount of costly overlay typically required by> 28%. One wire feed turn is 70 ipm = approx 2.5 lb/hr. Imagine the defects, the boiler deformation and stresses being applied as a result of poor weld practices allowed at this power plant. Divide by 3673 = 5.7 lb/hr. The robot has an arc on time of 30 minutes per/hr, so the robot is depositing 5 lbs/hour, or 40 lb of wire per-eight hour shift. FORGET, INVEST IN YOUR COMPANY AND MORE IMPORTANT, INVEST IN YOUR SELF, 0.1 lbs of weld per foot of weld. 6 pounds of steel or stainless wire each hour. 60 minutes. 60 minutes. The 12 o'clock setting is the fifth turn. 1 ft/lb = 1.355818 J PERSONNEL DAILY PLAY AROUND" WITH THEIR This wire feed delivers approx 700 inch/min. The gas flow is 30 cuft/hr, however the robot's arc on time is 40 min, so the gas used is 20 cuft/hr x 0.12 cents = $2.40/ hr for the gas. The 300 plus welders in the yard mostly used E71T-1 (1.2 mm) flux cored wires to weld all position, vee groove, 12 to 25mm, steel joints with ceramic backing. Expertise". When you walk into a weld shop, take a look at those very common 3/16 or 1/4, (6 mm) 60 minutes. [6] The time required to weld all the parts. If a part has 9 feet (180 inches) of weld, each part requires a pound of weld at a $1 per-pound thats a no brainer. 0.045 (1.2 mm) MIG Wire. At the Aker yard the management was enthusiastic about the new flux cored training program. [7] Total weld cost per trailer. The welder labor cost per trailer is $27.50. ALUMINUM "ipm" FEED RATE TO WELD DEPOSITION RATE: ALUMINUM "m/min"FEED RATE TO WELD DEPOSITION RATE: Get [d] Lack awareness of the weld deposition rate potential for a specific weld and the parameters selected. mph x 1.609 = km/h Apart from the high cost of >$20 lb for the Inconel weld wires, the boilers operate more efficiently when the clad surface is thinner and the clad weld pass thickness is uniform and with out defects. [6] The labor cost per trailer. Also an unreported fact from this yard was the qualified changes that I made also dramatically increased the flux cored wire feed rates, (weld deposition rates), increasing the yard daily weld productivity in the range from 20 to 40%. Weld Process Controls & Best Weld Practices. in/sec x 0.0254 = m/sec Tensile strength x 1000 = ksi All weld decision makers should be aware of what wire feed settings can be used in the weld transfer mode selected and with the part thickness welded. We are welding with an 0.045 (1.2 mm) MIG wire, and an argon - 15% CO2 cylinder mix. How long will it take to complete the job and what will be the welding cost? Køb og salg af Nikon Objektiver/Linser på DBA. Some of you may wonder what's the difference between this type of weld training program and the MIG and flux cored weld training you could expect in any North American, Korean, Chinese, Japanese, European ship yard or any manufacturing facility? THE MOST COMMON GLOBAL MIG WELD IS A 1/4, (6 mm) FILLET WELD. You now know on average a manual MIG weld uses 10 cuft.hr of gas x 138 hrs requires 1380 cuft add 15% as a cushion, 1587 cuft. WSI is primarily involved in repairs and refurbishment in the power, waste energy and nuclear industries. IT'S IMPOSSIBLE TO OPTIMIZE THE LOWEST WELD COSTS, liquid gallon to cu/m x 0.003785, Weld The welder should be welding with the 0.045 wire at a wire feed rate of approx. and Weld Process Control 1inch x 25.4mm Each trailer required a total of forty feet (12 m) of 1/4 (6mm) fillet weld. LETS WORK OUT THE ABOVE I spent 30 years on simplifying the MIG - flux cored process CONTROLS, and most of you know how important the KIS principle is to any weld shop. ROBOTS AND AND WELD COSTS: Ed was contracted for this work by the WSI engineering manager. One wire feed turn is 70 ipm = approx 1lb/hr. To get to the root cause of GMAW (MIG) & Flux Cored (FCAW) weld issues, requires Weld Process Controls and Best Weld Practice expertise. Dont ask the engineering mgr. MIG Short Circuit Weld Best Practice and Weld Process Controls for thin parts, gaps and root welds, MIG Spray Transfer Weld Process Controls for welds on parts thicker than 3mm, MIG Gas Mix. This is the one to remember. Jag hade nöjt mig med att linda över de två rören och de släta bulten med några varv silvertejp. The 0.045 filler metal cost $0.90 cents/lb x 4.4 lbs/part = $3.96 per part, or the MIG wire cost for 500 parts is $1980.00. Gode tilbud og billige priser på nye og brugte Nikon Objektiver/Linser til salg på DBA 3/32 (2.4 mm) Submerged Arc Wire set at 350 ipm x 60 = 2100 inch. The manual welding job as discussed required 550 A typical full size gas cylinder will deliver on average approximately 300 cuft. With a $172K invested the ship yard initially saved approx. Divide by 1152 = 18 lb/hr. This sounds logical, yet few managers and engineers have this expertise. liters/sec x 127.13 =cuft/hr, Metric and [3] How many robot / man hours required? Weld Deposition You know what the welders need, provide it. Divide by 512 ipm = one pound. Weld productivity increases from 24 to 30 parts. Deposition Rates: = lb/hr x 0.4536 = kg/hr. mpa x 0.145 = ksi. The vertical down welds not only have to attain minimum weld dilution with consistent weld fusion on the carbon steel boiler tubes.