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It's All About Productivity: Hou Ston, Texas US A WWW - Weld Revol Ution .Co M
It's All About Productivity: Hou Ston, Texas US A WWW - Weld Revol Ution .Co M
H o u s t o n , Tex a s U S A
w w w. w e l d re v ol u t i o n . c o m
YouTube Channel
https://www.youtube.com/user/weldrevolution
https://youtu.be/z58texOgKdQ
How does it work?
centrifugal force
all position welding
high deposition
High Speed Video
https://youtu.be/wp3QH0Uij4s
30o Weld Joint
https://youtu.be/U15SYL3s8_k
15o Weld Joint
https://youtu.be/uXrWaM5A2uU
40% Increased
Productivity
v
productivity case studies
T h e s av i n g s p r e se n t e d ar e f o r i l l u s t r at i o n p u r p o se s
o n l y . T h ey a r e ex am p l e s o f p o t en t i a l s a v i n g s a n d
i n c l u d e es t i m at e s o f c u r r e n t c o st s , l a b o r &
o v e r h e ad r a t e s, e t c .
Sample 1
SpinArc® Productivity
Solution
Reduced Bevel (60 30 ) o
30
Total Cost Per Foot of Weld Why choose SpinArc®?
Current
25 • 70% weld cost reduction
SpinArc®
20 • 75% productivity increase
15
$25.60 • 40% less weld metal
10
• Reduced distortion
5
$7.75
• No slag removal
0
SpinArc® is 3x faster
Sample 2
SpinArc® Productivity
Solution
Reduced Bevel (37.5 20 ) o
SpinArc® is 2x faster
SpinArc® Productivity
Solution
Square Butt Joint
• 60o bevel to square butt with SpinArc®
• 1G steel backing
• 1.25” T (32 mm)
• 1/16” (1.6 mm) ER70S-6, 90/10 Ar/CO2
• 3/8” (9.5 mm) groove width
• 14 lbs/hr (6.3 kg/hr)
• 13 ipm (33 cm/min) travel speed Sample 3
Weld Cost ($)
30
SpinArc® • 60% productivity increase
25
• 60% less weld metal
20
15
$34.55
• Reduced distortion
10
$13.33
• No slag removal
5
0 • No beveling
SpinArc® is 2.5x faster
SpinArc® Productivity Sample 4
Solution
Square Butt Joint
• 30o 1-sided weld to sq. butt w/ SpinArc ®
• 2G, no backing
• 0.25” T (6.3 mm)
• 0.052” (1.4 mm) ER70S-6, 80/20 Ar/CO2
• 1/16” (1.6 mm) root opening
• 10 lbs/hr (4.6 kg/hr)
• 22 ipm (56 cm/min) travel speed
Weld Cost ($)
$0.59
• No slag removal
• No beveling
Solution
Square Butt Joint
• 60o bevel to square butt with SpinArc®
• 1G, ceramic backing
• 3/8” T (9.5 mm)
• .045” (1.1 mm) ER70C-6, 90/10 Ar/CO2
• 1/4” (6.3 mm) root opening
• 16 lbs/hr (4.6 kg/hr)
• 21 ipm (53 cm/min) travel speed
Weld Cost ($)
SpinArc® is 3x faster
SpinArc® Productivity Sample 6a
Solution
¼” Fast Fillet Weld
• 29 to 40 in/min travel speed with SpinArc®
• 2F
• 3/8” T (9.5 mm)
• .045” (1.1 mm) ER70C-6, 80/20 Ar/CO2
• 15.5 lbs/hr (7.1 kg/hr)
• 40 ipm (102 cm/min) travel speed
Weld Cost ($)
Solution
3/8” Big, Single-Pass Fillet Weld
• 2 passes reduced to 1 pass with SpinArc®
• 2F
• 3/8” T (9.5 mm)
• .1/16” (1.6 mm) ER70C-6, 80/20 Ar/CO 2
• 12.8 lbs/hr (5.8 kg/hr)
• 11.5 ipm (29.2 cm/min) travel speed
Weld Cost ($)
SpinArc® is 2x faster
SpinArc® Productivity Sample 8
Solution
Vertical Down
• Changed .045” FCAW-G V-up to .052” solid
wire vertical down SpinArc®
• 3G down
• 3/8” T (9.5 mm)
• .052” (1.4mm) ER70S-6, 82/10/8 Ar/He/CO2
• 10.8 lbs/hr (4.9 kg/hr)
• 18 ipm (46 cm/min) travel speed
Weld Cost ($)
SpinArc® is 3x faster
Clad Overlay
• shallow, consistent penetration
• flat bead profile
• low dilution, 5-10% Fe in 1st layer
• Solid, metal core, flux core wires
• 5 – 10 times faster than TIG
• 12 – 15 lbs/hr (5–7 kg/hr)
• 1G, 2G, 3G down 1.8mm Single
Layer Deposit
Clad Overlay Vertical Down
https://youtu.be/2ypRMYEdMXE
Heavy Wall Pipe
• 10” x 1.375” WT (254 mm x 25mm
WT)
• X65 pipe
• U-Groove (2-3 deg. bevel)
• 1.0 mm ER-80Ni1
• GMAW-P w/ 90Ar/10CO2
• TS: 24 in/min (50 cm/min)
• WFS: 585 in/min (23 m/min)
• DR: 12 lbs/hr (5.5 kg/hr)
• Bug-O Piper Plus w/ auto height
control
5G Pipe Welding Video
https://youtu.be/lQ_t47hW2Rg
1G Plate
5/16” (8 mm)
Pass 1 Pass 2
WFS 550 ipm 625 ipm
(14 m/min) (16 m/min)
Root
Middle
V ick e r s M icr o h ar d n e ss (1 0 0 0 g lo ad )
100.0
120.0
140.0
160.0
180.0
200.0
220.0
240.0
260.0
280.0
300.0
0 .0 0
0 .0 5
0 .1 0
0 .1 5
0 .2 0
Microhardness
0 .2 5
0 .3 0
Cap
0 .3 5
Root
Middle
0 .4 0
0 .4 5
Distance from first indentation (inch)
0 .5 0
0 .5 5
0 .6 0
0 .6 5
• Full Pen/One-sided with ceramic backing ¼” (6 mm)
• .045” (1.1 mm) E80C-Ni1 H4 metal core Single Pass
• Miller CV, 90Ar/10CO2
• Groove: Square Butt
• Root Opening: 3/32” (4.7 mm)
• CTWD: 7/8” (22 mm)
• Travel Speed: 30 in/min (76
cm/min)
• WFS: 750 ipm
• Dep Rate: 22 lbs/hr (10
kg/hr)
• Voltage: 28.5
• Spin Speed: 3,500 rpm
• Spin Diameter: 5 mm
Cap
Root
Middle
V ick e r s M ic r o h a r d n e s s (1 0 0 0 g lo a d )
100.0
120.0
140.0
160.0
180.0
200.0
220.0
240.0
260.0
280.0
300.0
0 .0 0
0 .0 5
0 .1 0
0 .1 5
0 .2 0
Microhardness
0 .2 5
0 .3 0
Cap
Root
0 .3 5
Middle
0 .4 0
0 .4 5
0 .5 0
Distance from from first indentation (inch)
0 .5 5
0 .6 0
0 .6 5
0 .7 0
Distortion Comparison
¼” (6 mm) Single Pass
SpinArc® Solution:
• 15o reduced bevel
• 40% weld Metal, full fusion
• 5 passes
• 0.045” (1.2 mm) solid wire
• 450 ipm (11.4 m/min) WFS
• Root to cap
• Meets Customer Expectations
15° Beam-to-Column
Problem:
• Fusion to the bevel side
• Joint is notorious for LOF (bevel side)
• Large bevel, typically, 37.5o included angle
SpinArc® Solution:
• Equal toe fusion
• Spin allows for fusion on both walls
• 40% less weld metal and time
• 4 passes
• .052” (1.3 mm ) solid wire
• 575 ipm (14.6 m/min) WFS
• 18 ipm (45.7 cm/min) Travel Speed
• Root To cap
Procedure Qualification
R&D Project Objectives:
Passed
Cross Weld Tensile Tests
CSA ASME
Specimen Ultimate Tensile Specim Ultimate Tensile
# Strength (psi) en # Strength (psi)
1C 72,485
1A 72,137
2C 70,232
2A 73,120
3C 71,329
4C 70,238 3A 67,941
5C 72,246 4A 71,484
6C 70,331 6A 73,694
*The minimum specified Ultimate Tensile Strength of these joints was 58,000 psi
Comparison of SpinArc to SAW
CSA W59 Prequalified Joint Preparation
As per CSA
0.37 W59 S2-4
5
0.3 in 0.5 in
SpinArc® SAW
Variable SpinArc® SAW
Wire Specification ER70S-6 (ER495-6) EM12K
Wire Size 0.045” (1.2mm) 3/32” (2.4 mm)
Gas Mixture/Flux 90% Argon / 10% CO2 F7A4 (F49A4)
Flowrate 50 CFH (24 Lpm) NA
Voltage 28 27
Wirefeed Speed 325 IPM (138 mm/s) 110 IPM (46.5 mm/s)
Travel Speed 24 IPM (10.2 mm/s) 27 IPM (11.4 mm/s)
1” (25.4mm) Root, 5/8” (16mm)
CTWD Successive 1” (25.4 mm)
Spin Diameter Setting 3 NA
Spin Speed 750 NA
Spin Direction Clockwise NA
Weld Profile Comparisons –
Hardness
SAW SpinArc™ Hardness Of SpinArc® and SAW
213.64
203.06
195.36 193.9
181.7 182.22 182.66
Hardness Vickers
164.96
Heat Affected Zone of Bay Region Grain Refined Weld As Deposited Weld
the Fill Passes Metal Metal
Cost and Time Comparisons
v
Groove Designs Backing or
Thickness Groove Width
Root Land
1/2“ – 1 ¼” 3/8”
Needed
(12-32 mm) (10 mm)
Welding in Groove
1/4” – 3/8” 3/32” – 1/8”
Needed
(6-10 mm) (2-3 mm)
Example:
35% efficiency improvement
$55.00/ft. ($17/m) cost reduction
x 1,500 ft. (457 m) per month
=$75,000/month savings
Typical Operating Ranges - Steel
8
7 Clad Overlay
Spin Diameter Setting
6
5 Plate Square Groove Butt
4
Sheet & Plate up to ¼”
3
2 Fillets Pipe Narrow Groove
1
5500
5000
4500
4000
Recommended
3500
Operating Range
Flexure Crank
3000 Max RPM
Setting
2500
Recommended
1 5500
Operating Range
2000 2 5500
1500 3 5500
1000
4 4500
5 3500
500
6 2750
0
1 2 3 4 5 6 7 8 7 2000
Spin Diameter (Crank Setting) 8 1200
Productivity
STUDIES
Convention SpinArc®
al
¾” (19 mm) plate example:
52% cost reduction
0.4 month payback period
MA-400 SpinArc System ®
Mechanized SpinArc® System
v
p l u g & p l ay fo r a n i n sta nt u p g ra d e
SpinArc® Control Box
SYSTEM
Control Cable
SpinArc® Torch
MA-400
SpinArc® System
System includes…
SpinArc® torch and cable, control box, & control
1.75” (44 mm)
cables
IP51
Product Length, L
Number
Spin Diameter
Settings (1-8)
Spin Speed and Diameter
Affect of Spin Speed (RPM) on Spin Diameter:
https://youtu.be/23r348Rej4g
Piper Plus
– Integrated SpinArc® controls
– Inclinometer
https://youtu.be/rih-Z4hyeOw
Pipe Welding
BUG & BAND
Flexible
MECHANIZATION
Semi-Automatic
HAND WELDING KIT
Automation
Systems
Robotic
INTEGRATION
it’s all about
PRODUCTIVITY +
QUALITY
less weld metal consistent HAZ
reduce over welding fast travel speeds
cut overall welding costs control penetration
minimize distortion & low dilution for
warpage cladding/hardfacing
v
Weld Revolution
19511 Wied Road
Spring, TX 77388 USA
832-585-1244
sales@weldrevolution.com
www.weldrevolution.com
Customer Assistance Policy
Weld Revolution LLC does not warrant or guarantee or assume any liability with respect to any information or advice given. Our
employees are not in a position to verify the information provided or to evaluate the engineering requirements for any customer.
Additionally, the provision of any information or advice does not create, expand, or alter any warranty on our products. Any express
or implied warranty that might arise from the information or advice, including any implied warranty of merchantability or any
warranty of fitness for any customers’ particular purpose is specifically disclaimed. The selection and use of specific products sold
by the Company is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the
control of the Company affect the results obtained in applying these types of fabrication methods and service requirements.