Cost and time calculations using different welding technologies

Cost calculation and optimisation of welded steel structures

<p>Cost is a significant consideration in the design of engineering constructions. Because welding is an expensive fabrication method, cost comparison helps determine the most cost-effective structural variant. Structural optimization is a design approach for finding better solutions that meet technical requirements. Design and manufacturing limitations provide safety and producibility while minimizing a cost function to achieve economy.</p><p>Another issue is the environmental impact of welding. The optimisation process is divided into two sections. The first is the cost calculation, which takes into account various welding technologies. The second minimizes environmental effects by considering the potential for global warming, acidification, and eutrophication caused by CO, CO2, NOx, N2O, SO2, and other fumes produced by welding. A numerical example illustrates the computation procedure.</p>

This article analyses cost estimations with different welding technologies using global and local methodologies. In structural optimisation these costs are the goal functions to be minimised. We consider the relationship between design and fabrication technology, as well as the economy, using optimisation. These three elements work together to assist us in determining the best option. Only those cost elements that are directly relevant to the structural dimensions are considered in the local approach. A real structure’s cost function may comprise material costs, assembly costs, and other fabrication costs, such as welding, surface preparation, painting, cutting, edge grinding, and creating geometry.Welding is the most common industrial procedure for combining metals, but it is also a significant producer of harmful fumes and gases. Depending on the welding technology, the amount of CO2, CO, CH4, NOx, etc., can be different. The global approach considers environmental issues such as global warming, ozone depletion, acidification, eutrophication, photochemical ozone production, and abiotic depletion. LCA is an objective approach for analysing and implementing alternatives to enhance the environment, as well as assessing the environmental consequences of a product, process, or activity.KeywordsLife Cycle AssessmentWelded structuresCost calculation

The development of welding technology in this era took place rapidly, especially in the sector of new ship building and ship construction repair. Incorrect welding activities often cause delays which cause costs, time and consumables losses. In order to develop the speed and efficiency of the welding work, it is mandatory to determine a welding method that is suitable for the site conditions. This study provides a choice of three welding methods consisting of the SMAW and FCAW welding methods based on their strength and economic value. To strengthen the results of welding can be tested with a destructive test consisting of a tensile test, bending test and impact test. Next, the calculation of the welding cost per kg, welding speed per meter and electrode consumption is carried out to find out the difference in the economic value of all the welding materials. When tested, it was found that there was no difference in tensile strength between SMAW and FCAW.
 Welding method, maximum 1%, but SMAW welding method has 4% better yield strength than FCAW welding method. The ductility value of the FCAW welding method is 34% better than the SMAW welding method. The FCAW welding method has 67% better economic value when compared to the SMAW welding method. The FCAW welding method has a speed of 72% better than the SMAW welding method, and the FCAW welding method is 50% more efficient than the SMAW welding method.

In this era, the growth of welding technology is very fast, especially in newship building and repairing ship construction. The welding work often rise the delaying which cause of lost of cost, time and material consumables. Developing of speed and efficient welding work have to choose the welding methode to be suitable with site condition. This research will explain the differences of three welding methods consist of SMAW, FCAW and SAW weld methode based on strengthening and economic value. The strengthening of welding result are tested by dectructive test consist of tensile, bending and impact test. It carried out the calculation of weld cost per kgs, weld speed per meter and electrode consumption to know the differences of economic value for all that welding material. The test result showed that no differences of tensile strength between SMAW, FCAW and SAW welding methode, max. 1 %, but SMAW weld methode have yield strength 4 % better than FCAW weld methode and 14 % better than SAW weld methode. FCAW weld methode ductility value 34 % mare than SMAW weld methode and 37 % more than SAW weld methode. FCAW weld methode have economic value 67 % more than SMAW weld methode and 42 % more than SAW weld methode. SAW weld methode on horizontal weld position have speed 63 % more faster than FCAW weld methode and 72 % more faster than SMAW weld methode. SAW weld methode have electrode consumption 6 % more efficient than FCAW weld methode and 50 % more efficient than SMAW weld methode.