![]() Statistics in my books say over 100 hours of training is required to obtain an acceptable degree of proficiency with a stick welder. I imagine it aggrivates the hell out of his welders, but they say 8 or 9 out of 10 rods will work perfectly if it is bought well in advance and allowed to sit in a very dry place for a while.Ĥ) Training a guy to weld for you SMAW takes a long time. I know a guy who pays pennies per pound of this stuff in E6010 stock. But the transfer efficiency is much lower.ģ) In spite of these costs, you can push costs still lower by using "junkyard rod", or stuff that welding supply places accidentally allow to get wet. 6010 should only run about $1.25 per pound. Typically outdoor fencing kind of work deals with E6010 rod, sometimes 6011 for the old timers or if you only have an AC buzz box. Over longer periods of time though welding out of position means stopping to clean your nozzle frequently enough that you waste your time savings.Ģ) E71TS wire costs me $6 per pound, sometimes a little more or a little less. My experiences and reading show things like this:ġ) FCAW is a nice process for burning down patch jobs. There are still obvious advantages and disadvantages to either process that will inherently make one more cost effective than the other. I will point out the obvious and say this is something of a loaded question. SMAW has its uses, but on plain costs GMAW wins. Their calculated cost per foot of weld was $0.41 for GMAW and $.78 for SMAW. The cost of the use of GMAW weld was only 47% of the cost of the SMAW weld (same weld size, a 1/4 inch fillet weld, comparison was based on using 1/16 inch spray-arc GMAW versus 3/16 E-6024 SMAW and a labor rate of only $15/hr). (source of percentages comes from ESAB's website)ĮSAB also lists a sample GMAW-vs-SMAW weld cost calculation. And that doesn't consider labor time, just the 'raw' filler used. So you'd have to buy/use about 143 lbs of 'stick' to get the same amount of weld bead as105 lbs of GMAW filler. SMAW deposition typical efficiencies are in the range of 68-70%. As opposed to spatter and slag and rod-ends/stumps.įCAW deposition typical efficiencies are in the range of 84-89%. That means that out of every 100 lbs of filler used, 95-98 lbs turned into actual weld bead. GMAW deposition efficiencies are usually in the range of 95-98%. No slag to deal with, no electrode changes (except when changing out the empty spool/roll), mostly just repositioning of the worker/torch. That covers electrode changes and de-slagging.Īrc-time for GMAW is around 50%. The majority of the cost of a weld is labor, prep and weld and post (cleanup and rework).Īrc-time for SMAW (aka stick) is about 20%. The cost of the wire/stick/filler is typically only about 15% of the cost of the weld.
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