I currently have an Excel Spreadsheet for sale on my website. The spreadsheet has 10 different joint configurations to choose from. There is also a sheet to help you calculate wire feed speed and deposition rates based on the length of wire fed for a given period of time.
All sheets are capable of converting from English to metric units.

The output page produces Shop productivity in lbs of wire per 8 hr shift along with the amount of weld wire to order, number of gas bottles to order, total number of welding hours, total cost, deposition rates, and estimated number of passes required. There is also a row that shows the percent savings between two welding processes plus more. There is a free demo you can download which is for estimating the cost of fillet welds only.

Check it out and let me know what you think.

Mark Mruczek
Senior Welding Engineering
Mruczek Welding Engineering
mailto:mmruczek@atlanticbb.net
Web site: http://www.mruczekweldingengineering.citymax.com/products.html