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How to Reduce The Costs of Welded Parts

Welding contractors have begun to realize the largest cost associated with welding in the field is labor. New innovative welding solutions have been developed to increase productivity thus reducing the cost of labor in this field. It’s time to ask yourself am I get the best service for my projects. Is it time to update my welding service or supplier? Approximately 80% of the cost of a field weld is labor. Welders are highly skilled craftsmen but the environment and other Jobsite activities often limit the productivity of your workforce. The other factor impacting productivity and quality on a Jobsite is the evolving workforce. Many seasoned welders are retiring and it is difficult to replace 30 or 40 years of experience as the industry changes. New technologies can improve production safety and quality in this field. Think about cell phones and televisions they look drastically different now than they did 10 years ago. These advancements and technologies hold true for the welding industry. Think about what level of technologies your suppliers using in your welding projects. Simple technologies like remote controls can improve quality safety and productivity on job sites.

Design and Other Price Influences On Welding Processes

Probably the most crucial reason for making cost calculations is to identify ways in which manufacturing costs can be reduced. The costs are influenced by the design stage, with further input factors all through to manufacturing. Some examples are given below. The biggest cost of manual welding is labor cost. One way of reducing it’s to introduce automation or fixturing, described below. The various portions of the total job time can be affected: a welding method with a higher deposition rate reduces the arc time while changing the method completely might also make it feasible to reduce the time needed for changing electrodes, slag chipping and spatter removal, thereby reducing the total time.

Equipment to hold or manipulate the workpiece to provide a good welding position assists welding. Planning of the work, too, is very important, as perhaps only 30 % of the total time is productive arc time. It can sometimes be possible to avoid making pointless welds or to use other production processes like bending. A few of the work time is the arc time. Even with a given welding method, it may still be possible to improve this by the correct choice of welding process parameters and electrodes, and/or by avoiding depositing more weld metal than necessary. The design stage, for instance, specifies the joint design and throat thickness of fillet welds. The joint design can be like to minimize the amount of weld metal required, naturally subject to the necessary performance requirements. Too large a throat thickness always results in more weld metal that is needed: a throat thickness of 5 mm uses 60 % more weld metal than does a throat thickness of 4 mm. it’s also important to plan joint preparations, bringing together and holding the parts and welding so no more weld metal than necessary is deposited: this will also have the additional advantage of reducing welding deformation. If, in addition, the penetration of the fillet weld can be utilized to reduce the nominal throat thickness, there’ll be a further reduction in the quantity of weld metal. The use of filler materials may also be influenced, although this cost needs to be related to the labor cost. In case the labor cost can be reduced by much much much more efficient welding, reduction of preparation and finishing, like spatter removal, avoidance of two-sided welding, improved quality, etc., additional cost for filler materials can be justified. Bear in mind, too, the overall production process. The correct quality of materials, fillers, cautious joint preparation and bringing together of parts all assist welding, reducing the overall time and having the least possible effects on other processes. A properly made weld generates fewer problems of examination and corrections.