Podstawowymi czynnikami wpływającymi na osiąganie zysku są koszty wytwarzania oraz cena sprzedaży. W związku z tym, że cena sprzedaży zależy od relacji między popytem a podażą, głównym źródłem ...zwiększania zysku firmy wytwarzającej konstrukcje spawane jest obniżka kosztów produkcji i/lub wzrost mocy produkcyjnej. Organizacja pracy oraz odpowiednie monitorowanie parametrów ekonomicznych zwiększa wydajność. Istotnym aspektem jest również szybkość i aktualność przekazywanej w firmie informacji. W artykule przedstawiono i scharakteryzowano strukturę kosztów spawania. Przedstawiono również oprogramowania wspomagające obliczanie kosztów spawania. Calculating welding cost using information systems Abstract The main factors affect the profit are production costs and selling price. Therefore, the selling price depends on the relation between supply and demand, the main source increasing the company’s profit producing welded structures is to cut production costs and/or increase production capacity. Work organization and adequate monitoring of the economic parameters increases productivity. An important aspect is the speed and topicality of information which is transferred between departments in company. The article presents and characterized the structure of welding costs. It also presents the software which support the calculation of the welding costs.
Nine gas metal arc welding (GMAW) processes for stainless steel were assessed for fume generation rates, fume generation rates per g of electrode consumed, and emission rates for hexavalent chromium ...(Cr
6+
). Elemental manganese, nickel, chromium, iron emissions per unit length of weld, and labor plus consumables costs were similarly measured. Flux-cored arc welding and shielded metal arc (SMAW) processes were also studied. The objective was to identify the best welding processes for reducing workplace exposures, and estimate costs for all processes. Using a conical chamber, fumes were collected, weighed, recovered, and analyzed by inductively coupled atomic emission spectroscopy for metals, and by ion chromatography for Cr
6+
. GMAW processes used were Surface Tension Transfer, Regulated Metal Deposition, Cold Metal Transfer, short-circuit, axial spray, and pulsed spray modes. Flux-cored welding used gas shielding; SMAW used E308 rods. Costs were estimated as dollars per m length of a ¼ in (6.3 mm) thick horizontal butt weld; equipment costs were estimated as ratios of new equipment costs to a 250 ampere capacity SMAW welding machine. Results indicate a broad range of fume emission factors for the processes studied. Fume emission rates per g of electrode were lowest for GMAW processes such as pulsed-spray mode (0.2 mg/g), and highest for SMAW (8 mg fume/g electrode). Emission rates of Cr
6+
ranged from 50-7800 µg/min, and Cr
6+
generation rates per g electrode ranged from 1-270 µg/g. Elemental Cr generation rates spanned 13-330 µg/g. Manganese emission rates ranged from 50-300 µg/g. Nickel emission rates ranged from 4-140 µg/g.
Labor and consumables costs ranged from $3.15 (GMAW pulsed spray) to $7.40 (SMAW) per meter of finished weld, and were measured or estimated for all 11 processes tested. Equipment costs for some processes may be as much as five times the cost of a typical SMAW welding machine.
The results show that all of the GMAW processes in this study can substantially reduce fume, Cr
6+
, manganese and costs relative to SMAW, the most commonly used welding process, and several have exceptional capabilities for reducing emissions.
Selecting a welding process for a given application is crucial with respect to the sustainability of part manufacturing. Unfortunately, since welding processes are evaluated by a number of criteria, ...preferences for one or the other process can be contradictory. However, the prevalent procedure of weight assignment for each criterion is subjective and does not provide information about the entire solution space. From the perspective of a decision maker it is important to be able to assess the entire set of possible weightings and answer the question which welding process is optimal for which set of weights. This issue is investigated by means of a weight space partitioning approach. Two welding processes are considered with respect to three criteria that reflect their economic and environmental performance. In order to find the most sustainable welding process the underlying weight space partition is evaluated.
Neste trabalho foram calculados e comparados os custos de soldagem associados a cada um dos ensaios realizados, como forma de determinar parâmetros operacionais adequados e economicamente viáveis ...para soldagem com o processo MIG/MAG com transferência metálica por curto-circuito, visando uma correta deposição de revestimentos com ligas de níquel sobre um substrato de aço C-Mn. O número de ensaios a serem realizados, foi determinado pelo uso do método Taguchi que dividiu os ensaios em duas matrizes L9, resultando num total de 18 ensaios. Na comparação dos gastos despendidos em cada um dos ensaios foi utilizado o custo direto total da soldagem de um revestimento com 55 mm de largura e 190 mm de comprimento, utilizando uma sobreposição de 50%. Com base nos resultados dos ensaios foram pré-selecionados quatro ensaios (R7, R11, R12 e RC4), dentre os quais o ensaio R11 apresentou o menor custo. Mas vale ressaltar que nos quatro ensaios pré-selecionados o material de adição utilizado foi a liga 625, pois esta liga apresentar um custo do arame-eletrodo muito inferior as demais ligas (C-276 e 686). Assim a escolha do material de adição para aplicação do revestimento ficou restrita somente a liga 625.
To provide quantitative information to choose the best welding processes for minimizing workplace emissions, nine gas metal arc welding (GMAW) processes for mild steel were assessed for fume ...generation rates, normalized fume generation rates (milligram fume per gram of electrode consumed), and normalized generation rates for elemental manganese, nickel, and iron. Shielded metal arc welding (SMAW) and flux-cored arc-welding (FCAW) processes were also profiled. The fumes were collected quantitatively in an American Welding Society-type fume chamber and weighed, recovered, homogenized, and analyzed by inductively coupled atomic emission spectroscopy for total metals. The processes included GMAW with short circuit, globular transfer, axial spray, pulsed spray, Surface Tension Transfer™, Regulated Metal Deposition™, and Cold Metal Transfer™ (CMT) modes. Flux-cored welding was gas shielded, and SMAW was a single rod type. Results indicate a wide range of fume emission factors for the process variations studied. Fume emission rates per gram of electrode consumed were highest for SMAW (~13 mg fume g(-1) electrode) and lowest for GMAW processes such as pulsed spray (~1.5mg g(-1)) and CMT (~1mg g(-1)). Manganese emission rates per gram of electrode consumed ranged from 0.45 mg g(-1) (SMAW) to 0.08 mg g(-1) (CMT). Nickel emission rates were generally low and ranged from ~0.09 (GMAW short circuit) to 0.004 mg g(-1) (CMT). Iron emission rates ranged from 3.7 (spray-mode GMAW) to 0.49 mg g(-1) (CMT). The processes studied have significantly different costs, and cost factors are presented based on a case study to allow comparisons between processes in specific cost categories. Costs per linear meter of weld were $31.07 (SMAW), $12.37 (GMAW short circuit), and $10.89 (FCAW). Although no single process is the best for minimizing fume emissions and costs while satisfying the weld requirements, there are several processes that can minimize emissions. This study provides information to aid in those choices. Suggestions for overcoming barriers to utilizing new and less hazardous welding processes are also discussed.
As an illustrative example of the economic design the minimum cost design of uniaxially compressed longitudinally stiffened plates is treated. In the cost function the material and welding costs are ...formulated considering two different welding technologies. Constraints on global and local stability as well as on the residual deformation due to eccentric weld shrinkage are considered. To fulfil the constraint on the tolerance prescribed for initial fabrication imperfection a relatively simple method is used to calculate the residual plate curvature. For the constrained function minimization a computer program of the Rosenbrock's mathematical programming method is used. The following optimum dimensions are determined: the thickness of base plate, the number and dimensions of stiffeners welded to the base plate by double fillet welds. The comparison of plates with flat and L-shaped stiffeners shows that the L-stiffeners are more economic than the flat ones and the residual deformation of plates with L-stiffeners is much smaller.
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The structure of a ship is completed by processing various steel plates and welding these plates. This butt welding of plates is defined as a seam in shipyards, and this study seeks to find a way to ...decrease costs by reducing the utilization of steel through effective seam arrangement. Seams were defined and classified according to purpose, and examples of “pieces” and “main plates” where seam creation had an economical saving effect were selected. For “pieces,” the change in the weight of steel utilized depending on the presence or absence of a seam was calculated, and the resulting change in cost increase was presented. In the case of the “main plate,” the quantity of seams does not change, but an example of cost variation due to the appropriate placement of seams is presented. Hence, a large difference was found in the costs of “pieces” depending on seam location. Thus, it was advantageous to create additional seams. For the “main plate,” it was found that narrow-width and wide-width materials incur more costs. This study demonstrates that creating seams is economically advantageous but may not be preferred owing to the increased workload from a production perspective.
Natural gas pipeline cost data collected by the Oil and Gas Journal (O&GJ) for interstate pipelines constructed from 1980 through 2017 were used to develop capital cost estimating equations that are ...a function of pipeline diameter, length, and U.S. region. Equations were developed for material, labor, miscellaneous, and right-of-way costs, the four cost components in the O&GJ data, for six different regions of the United States (U.S.). Each equation is a function of pipeline diameter and length. Adjustment mechanisms were then developed for converting the natural gas pipeline equations into equations for estimating the costs of hydrogen pipelines. These adjustments were based in part on an analysis completed by the National Institute for Standards and Technology (NIST). Here the results of this work were used to update cost models in the Hydrogen Delivery Scenario Analysis Model (HDSAM), developed by Argonne National Laboratory for the U.S. Department of Energy’s Hydrogen Program. Our analysis shows a wide range of pipeline cost across different U.S. regions, especially with respect to labor and right-of-way costs. The developed cost formulas for hydrogen pipelines are both important and timely as hydrogen is being considered as a zero-carbon energy carrier with the potential to decarbonize all energy sectors, and the cost of hydrogen transportation is essential for techno-economic analysis of its potential use in these sectors.
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