Cost of consumables and speed of weld

[TimeGun]

Please can someone give me some information and guidance?

I am a complete novice when it comes to welding, but have a precision engineering and mechanical workshop background; using lathes, mills and drills daily for over 35 years, I have always wanted to get to grips with welding and now may be my excuse to spend time learning and money on capital kit.

I am about to embark on the construction of a metal framed and clad workshop approx 5m X 7m.

The frame will be in 35 or 40mm x 3mm angle iron and made up from a series of about fifteen 2m X 1.5m sub frames all bolted together, the roof trusses will also be modular.

My dilemma:
Should I stick with what I already know (nuts, bolts taps and dies) to make each frame, or is it practical in time, and cost effective in consumables, to weld each frame together.
Each frame has 6 joints, lap or but, it will make little difference once clad.

My questions.

1. How many meters of weld am I likely to get out of a 5kg role of .8mm wire and how many meters for a 600g gas can. (using a Clark 100e or 135te mig). ?

2. How many hours of practice does it normally take someone to learn, before able to run a acceptable weld ?

3. Once I have mastered the art of basic welding (assuming I do), how long will it take to weld, say 100mm of joint in 3mm thick material.

Any other comments also gratefully received.

Thank you in anticipation.

Paul.

 

[gavuk]

Sorry i can't quantify gas usage or wire usage ,what i can say is forget the 600g disposable bottles and go for rent free Argon mix or co2 pub bottles ,mate of mine has just gone to co2 ,£15 for 15kg or was it 10kg?.and £40 for a reg and hose,i wouldn't expect you to use more than 1x 5kg of wire,would be much quicker than bolting ,i'm not sure about your joints though ,if you could post a sketch ?,with a welder there may be changes to make life easier or quicker,i come from a similar background and would weld given the choice especially if i could justify buying new kit and learning new skills ,maybe tap a local forum member to give you some pointers with the welding......

 

[rtbcomp]

I think I'd be inclined to stick weld that lot, much cheaper outlay than a MIG.

Like Gav says, forget disposable bottles.

 

[rtbcomp]

If you're working outside there is a chance that a breeze could blow the welding gas away, this means either erecting a screen, using gasless wire or stick welding.

 

[pedrobedro]

For your questions I think you are getting too involved in considerations which are not relevant to most people on here.
1. If you are not using the welder for 8 hours every day it will be more like how many weeks will you get out of a 5kg reel but don't consider the hobby gas cylinders if you are looking at the economics.
2. I have seen people who have made decent welds after 30 minutes and others who will never stick two pieces of metal together while they have a hole in their @rse.
3. Depending on your machine and your technique 100mm of weld might take you 20 or 30 seconds.

If you are building in sections working at ground level and bolting them together I have never had a problem with gas blowing away, just place yourself in the way of any draughts. It does sound like a stick welding inverter might be more use to you for what you are looking at doing and rods are cheap but the technique is more difficult to pick up.

 

[gavuk]

I would prob arc weld it to ,but then i would go for 5 or 6mm angle or 40/50mm box and forget the modular design.if i wanted to get a mig though i would design it around its capabilities....

 

[TimeGun]

Many thanks for all your advice and information, its down to a bit more head scratching I think.