Welders, shop supervisors, and even accountants are vested in determining how to assess welding productivity and its impact on a company's profitability. The consumable calculation formula for submerged arc welding (SAW) is essential for them, which changed to an excel file. Welding shops that perform high-volume tube and pipe welding processes or other types of repetitive repairs can generate production metrics that can be used to calculate welding productivity and monitor process improvements. This is despite the fact that calculating productivity can be a challenging and complicated activity. Common welding procedures for tubes or pipes, such as butt, fusion, narrow groove, and tube-to-tube sheet, can offer baseline data that can be used to quantify welding efficiency. 
The following are some potential factors that could be included in the final measures for measuring welding productivity:
- The number of units produced per day, week, month, and quarter depends on the manufacturing quantities.
- The amount of filler wire that was utilized, as measured in terms of wire weight or wire length consumed.
- Arc-on time is expressed as a proportion of the whole welding job and represented in hours per week, month, or quarter.
- Rates of scrap or reworked materials.
Each of these indicators provides information on welding productivity; nevertheless, it is impossible for a single summary metric to effectively provide insight into the various granular operations that influence total welding productivity. Because of this, it can be beneficial to look at productivity from more than one perspective simultaneously. The orbital welding technique is perfect for applications requiring high-quality welding and a high level of repeatability because it requires little intervention from the operator. Many different types of businesses have seen considerable productivity gains in their welding operations after switching from using manual processes to employing orbital welding techniques. The calculations used to quantify efficiency increases can differ from shop to shop, yet the benefits, both quantitatively and qualitatively, are impressive. 
Welding Consumables Calculation
Although it may appear difficult, determining the amount of weld metal required should not be difficult in most situations. The most straightforward method, short of having a computer program that does the calculations for you, is to make use of the tables that are included in The Procedure Handbook of Arc Welding. The data presented in Table 12-1 can be used to calculate the required weight of weld metal per linear foot of joint. This article provides information on fillet welds and groove welds, which can also be utilized for lap welds. The joint's specifics are all you need to be aware of at this point (leg size, bevel angle, root, etc.). If you do not have the tables from the Procedure Handbook, you can perform all of these calculations by hand in a fairly straightforward manner. We get phone calls from customers who want to know the criteria for the works they are quoting regarding the weld metal. When we have a conversation with the client, we will inquire about the total inches (or feet) of weld, as well as the type of weld and the sizes. When determining how much product they need to purchase, we will also need to know the procedure that is being utilized to take into account the efficiency of the electrodes. 
Welding Consumables Calculation for Piping
One customer of Arc Machines, a producer of corrosion-resistant flow sensors used in the food and beverage sectors, determines welding productivity based on how quickly pressure flow sensors are welded to the piping. The number of sensor joints, pipe size, and kind of piping the sensor will be welded to all affect the welding procedure. Combinations of the following are used in this manufacturer's process:
- A central casting that houses the sensor is connected to pipework by two to four weld joints on either side.
- from two to fourteen inches for joints
- Depending on the need for corrosion, Schedule 80 pipe may be made of carbon steel, stainless steel, duplex stainless steel, chrome-moly, or different nickel-based alloys.
An automated GTAW hot wire welding technique can replace a manual MIG welding process, allowing manual tasks that previously took a week to be finished in just one day. Only two welds have been rejected throughout four years of production and thousands of welds. The whole welding process time has been shortened even further due to this low rejection level. To ensure a clean inner bead, hundreds of fusion welds were required to install 6,000 linear feet of stainless-steel piping (with an outer diameter (OD) ranging from 1/2 inch to 4 inches and a wall thickness ranging from 0.035 to 0.085 inches) in one brewery. More than 90% of the welds were created using orbital welding processes. Pipes, tees, and elbows with an OD ranging from 1 1/2 to 4 1/2 inches were welded using modular weld heads; a typical two-inch OD weld required 1 1/2 minutes of arc time and 1 minute of gas purging to complete. The predicted number of person-hours needed to finish the task using manual welding techniques was lowered by 15-20%, and fabrication time was slashed by 50% using orbital welding techniques, greatly enhancing welding productivity. 
Welding Consumables Calculation Formula
The area of the metal that will be melted during the welding process is the cross-section area of a weld. Calculations can be used to determine this region. The size and shape of a weld determine its cross-sectional area. A rectangle or square size can be determined with a straightforward computation. Other forms, such as circles or ovals, need more intricate computations. The whole cross-sectional area of the weld must first be calculated as shown below: At = A X (100 + X)/100 Where: A is the area of the theoretical weld cross-section. X = Additional welding required due to weld surface reinforcing and oversizing (in percent) At is the weld's total cross-sectional area (includes excess weld) V = At × L L is the weld length (or total length of similar welds). Once you have all of the dimensions, calculating the Fillet Weld volume is quite straightforward. 
Using the formula below, determine the fillet weld area depending on the throat size. To determine the total volume or "weld weight" of weld material needed, multiply two measurements—area and weld material density—together. The number of electrodes necessary to deposit 1 kilogram of weld metal, or the weight of weld metal obtained from each electrode, can also be found by consulting the electrode manufacturer. W = V×M V is the total volume of deposited weld metal, including any excess weld metal. W is the weight of the deposited weld metal for the given length L. Tw = W/D D is the rate of weld metal deposition per hour. Tt = W/D x Dw Where Welder/operator work efficiency factor is denoted by Dw (arc time per hour expressed in decimal format) E = W/Dp Dp is the welding process deposition factor (deposited metal weight divided by electrode weight). G = Tw x (cu volume/hour) 
SAW Welding Consumables Calculation
Determining chances to increase welding process efficiency by utilizing new methods, technologies, and materials is the ultimate purpose of picking a method to assess welding productivity. One method that has the potential to increase productivity significantly is orbital welding. The use of orbital welding presents perfect prospects for measurable improvements in several tasks in a typical manual tube welding operation. Alignment: For a variety of tubing diameters, interchangeable orbital weld head cassette modules are created. Before welding, clamps hold and align the tubing or fittings, saving the time needed for manual tacking. Setup: Programmable orbital welding power supplies and controllers maintain weld schedules that include information on the OD, wall thickness, material, weld type (tube, pipe, fits), and welding variables (current, travel speed, pulsation, and time) of the pipe or fitting in question. When it comes time to weld, the controller's memory conveniently stores the exact weld schedule. 
Weld time: Weld schedules accurately manage welding operations, including wire feed, electrode angle, arc distance, pulsation, and travel speed. The variability of manual welding operations is eliminated by automated control employing improved welding settings, reducing arc duration and effectively producing consistent outcomes without sacrificing quality. Changeovers/downtime: Reduce downtime by switching quickly between different tube and pipe welding activities with the help of a large selection of modular weld heads and a library of welding schedules. Post-process rework: post-welding activities can be great, if not entirely, reduced with consistently high-quality welds. Time savings using orbital welding procedures can range from minutes to hours, depending on the type of welding process being used, as in the case of significant rework associated with a subpar manual weld. When assessing welding productivity, time savings in any one or more of these categories translate to considerable advantages in high-volume applications or recurring maintenance activities. 
Welding Wire Usage Calculation
How to estimate welding work costs is a question I get frequently. We may use basic algebra to determine how much shielding gas and welding wire are required for the project. Say a company must provide a price for 5,000 feet of 1/4-inch fillet welds. How much gas and welding wire will they require? Before responding, note that the way this question is phrased implies that the shop is already aware of the weld size and the job's length. The quote wisely includes the cost of shielding gas. The fillet weld parameters and weld metal weight per foot are shown in Table 1. These values are provided in Table 12-1 of the Arc Welding Procedure Handbook by Lincoln Electric (Cleveland, OH). How many pounds of welding wire should I use? Metal weld weight per foot x (feet of weld for the job) 
Example 1 With a 14-inch flat fillet, 5,000 feet will need pounds of welding wire (using values from Table 1). 5000 feet x 0.129 kg/ft Solid welding wire, 0.85 = 645 lb Cored wire: 0.129 kg/ft x 5000 ft = 759 kg You can compare costs when you know how much welding wire is required for a project. Welding wire costs vary by sort (solid or cored), diameter, and packaging (size of spools, drums, boxes, etc.). Thus, a price based on the welding process used in the shop can be precise (e.g., wire type, wire diameter, and the type of packaging). Production flow rate (SCFH) and welding hours affect how much shielding gas is used. the flow rate in SCFH (hours of welding) This article provides instructions on how to determine precise welding quotes. You may run your firm for profitability using math and numbers. Lower deposition and flow rates need more time and money to weld. This piece was inspired by Lincoln Electric's Regis Geisler, who made welding operations more profitable. 
How To Calculate Welding Consumables
No matter how you calculate productivity, there's always an opportunity for improvement. When it comes to defining how to quantify welding productivity across the various welding tasks a shop is responsible for, each shop will have its own unique methodology. Shops that perform significant volumes of welding operations have the advantage of being able to monitor production metrics in order to assess their productivity and locate areas in which they may improve by applying innovative techniques and technology. Regardless of the method that is utilized to determine welding efficiency, the examples that were presented earlier demonstrate that solutions involving orbital welding can have a considerable effect on the results of the process. In addition to an increase in productivity, orbital welding produces welds that are consistent, reproducible, and of high quality. This results in a significant reduction in the amount of time and money required for rework. 
Welding shops that are serious about increasing their production should seek out welding industry innovators such as arc machines, inc. Arc machines are able to give solutions that are tailor-made to satisfy every orbital welding requirement, thanks to their decades of experience in the field.