Does seamless fluxcored wire results in higher quality and less welding cost in shipbuilding?

Seamless flux-cored wires represent a remarkable innovation in the field of welding, particularly within the shipbuilding sector. These wires bring a host of benefits when compared to their traditional counterparts. A notable benefit is the potential for reduced welding costs. Below, we will explore the mechanisms through which seamless flux-cored wires can contribute to severe cost savings in your welding operations. 

How are the welding costs devided?

1 meter FCAW fillet weld with an height of 4 mm is costing approximately € 6,- per meter including labor, welding wire, gas and devaluation of welding equipment. We can see that the cost for welding is divided as follow:

Labor cost    80%   
Weldwire cost  7,5%  
Gas cost   7,5%  
Devaluation cost   5%  

 

Especially due to the high labor cost between € 40,- / € 60,- per hour in the Netherlands we see that 80% of the welding cost are absorbed by labor, so this is the part where we should put the focus on. If we manage to increase welding time with 10% only, we already saved 8% of the total weld costs. This means that with a better (sometimes more expensive) wire, welding costs are reduced.

 

By choosing for a Fluxcored arc welding wire (FCAW) over a solid welding wire (GMAW), we’re able to significantly boost the ampere output. The illustration below shows how an increase in amperage affects your welding costs.

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WELDING SEAM costs GMAW

the total price of 1 meter welding seam in PF position at 130 ampere (GMAW)

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WELDING SEAM costs FCAW

the total price of 1 meter welding seam in PF position at 240 ampere (FCAW)

In addition to the welding costs CEWELD AA R400 will help you also to achieve these goals
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AA R400 seamless rutile cored welding wire for positional welding
  1. 240 Ampere in PF position results in a deposition increase of 200%!
  2. Impact strength properties wen exceeding 2 kj heat input are still above 27 joules
  3. Copper-coated surface reduces tip replacements of at least 5 times
  4. Seamless means no redrying or special storage requirements, each spool can stay on the machine till next working day
  5. No risk of hydrogen cracks or porous welds due to moisture issues
  6. Less wires and procedures needed because of the -40°C approval
  7. Reduced slag system (12%) that results in more recovery and less waste
  8. No twist in the wire means excellent for robotic welding for starts on the correct spot
  9. No feeding issues even with single roll wire feeders and long torches

 

Discover detailed information on the CEWELD AA R400 by consulting its product sheet!
 

CEWELD AA R400

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