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SpinArc® Productivity Case Studies
The document discusses the Spinarc® productivity solution for welding, presenting various case studies that highlight significant reductions in weld costs, improvements in productivity, and decreased consumption of weld metal. Multiple samples illustrate the benefits of using Spinarc®, such as faster welding speeds and less distortion, with claims of cost savings of up to 70%. Additionally, it emphasizes that the information provided is illustrative and does not constitute a warranty or liability from Weld Revolution LLC.
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SpinArc® Productivity Case Studies
- 1. v productivity case studies weldingapplications The savings presented are for illustration purposes only. They are examples of potential savings and include estimates of current costs, labor & overhead rates, etc.
- 2. SpinArc® Productivity Solution ReducedBevel (60 30o) • Changed .045” FCAW-G to .052” MC SpinArc® • 1G ceramic backing • 3/4” T (19 mm) • .052” (1.4 mm) ER70C-6, 90/10 Ar/CO2 • 30o included angle • 1/8” (3.2 mm) root opening • 16 lbs/hr (7.3 kg/kr) • 15 ipm (38 cm/min) travel speed Sample 1 Why choose SpinArc®? • 70% weld cost reduction • 75% productivity increase • 40% less weld metal • Reduced distortion • No slag removal SpinArc® is 3x faster $25.60 $7.75 0 5 10 15 20 25 30 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 3. SpinArc® Productivity Solution ReducedBevel (37.5 20o) • .045” FCAW-G to 1/16” solid wire SpinArc® • 1G ceramic backing • 1” T (25 mm) • 1/16” (1.6 mm) ER70C-6, 90/10 Ar/CO2 • 20o included angle • 1/8” (3.2 mm) root opening • 12 lbs/hr (5.4 kg/hr) • 17 ipm (43 cm/min) travel speed Sample 2 Why choose SpinArc®? • 60% weld cost reduction • 50% productivity increase • 40% less weld metal • Reduced distortion • No slag removal SpinArc® is 2x faster $32.84 $12.54 $- $5.00 $10.00 $15.00 $20.00 $25.00 $30.00 $35.00 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 4. SpinArc® Productivity Solution SquareButt 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 Why choose SpinArc®? • 60% weld cost reduction • 60% productivity increase • 60% less weld metal • Reduced distortion • No slag removal • No beveling SpinArc® is 2.5x faster $34.55 $13.33 0 5 10 15 20 25 30 35 40 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 5. SpinArc® Productivity Solution SquareButt 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 Sample 4 Why choose SpinArc®? • 55% weld cost reduction • 60% productivity increase • 50% less weld metal • Reduced distortion • No slag removal • No beveling SpinArc® is 2.5x faster $1.42 $0.59 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 6. SpinArc® Productivity Solution SquareButt 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 Sample 5 Why choose SpinArc®? • 63% weld cost reduction • 70% productivity increase • 25% less weld metal • Reduced distortion • No slag removal • No beveling SpinArc® is 3x faster $6.98 $2.58 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 7. SpinArc® Productivity 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 Sample 6a Why choose SpinArc®? • 25% weld cost reduction • 30% productivity increase • Consistent, flat bead profile • Good tie-in to each plate and root SpinArc® is 1.4x faster $1.70 $1.29 0.00 0.50 1.00 1.50 2.00 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 8. SpinArc® Productivity 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/CO2 • 12.8 lbs/hr (5.8 kg/hr) • 11.5 ipm (29.2 cm/min) travel speed Sample 6b Why choose SpinArc®? • 25% weld cost reduction • 30% productivity increase • Large, flat single-pass fillet • Good tie-in to each plate and root • Reduced distortion SpinArc® is 1.4x faster $5.59 $4.16 0.00 1.00 2.00 3.00 4.00 5.00 6.00 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 9. SpinArc® Productivity Solution Sample7 625 Clad Overlay • 2 passes reduced to 1 pass with SpinArc® • 1/8” bead thickness (3.2 mm) • .045” (1.1 mm) ERNiCrMo-3, 100% Ar • 14.5 lbs/hr (6.6 kg/hr) • 11 ipm (28 cm/min) travel speed • 1” (25 mm) bead width • 3.3 ft2/hour coverage Why choose SpinArc®? • 50% welding labor savings • 100% productivity increase • 50% less weld metal • Reduced distortion • Consistently achieve <10% Fe in 1 layer SpinArc® is 2x faster $46.67 $20.00 0 10 20 30 40 50 LaborCost($) Labor Cost Per Sq. Ft of Overlay Current SpinArc®
- 10. SpinArc® Productivity SolutionSample 8 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 SpinArc® is 3x faster Why choose SpinArc®? • 65% weld cost reduction • 65% productivity increase • 20% less weld metal • No slag removal • No beveling • Reduced distortion $11.08 $3.65 0.00 2.00 4.00 6.00 8.00 10.00 12.00 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
- 11. For more information WeldRevolution LLC 19511 Wied Road Spring, TX 77388 USA 832-585-1244 sales@weldrevolution.com www.weldrevolution.com
- 12. Customer Assistance Policy WeldRevolution 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.
Editor's Notes
- #3 Assuming 4000 ft of welding per month, 33% operating factor and $50/hr labor & overhead rate $420,000 savings in 6 months Payback = 3 days ROI = 5100% Does not include savings from reduced joint prep or electricity savings.
- #4 Assuming 4000 ft of welding per month, 29% operating factor and $50/hr labor & overhead rate4000 ft of welding per month Does not include savings from reduced joint prep or electricity savings. Payback = 3 days ROI = 5300%
- #5 Assuming 4000 ft of welding per month, 38% operating factor and $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings. $500,000 savings in 6 months 3 days payback 5790% ROI
- #6 Assuming 4000 ft of welding per month, 23% operating factor and $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings. $11,500 savings in 6 months 2.5 mo. payback 36% ROI
- #7 Assuming 4000 ft of welding per month, 23% operating factor and $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings. $97,000 savings in 6 months 14 day payback 1000% ROI
- #8 Assuming 10,000 ft of welding per month, 31% operating factor and $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings. $16,000 savings in 6 months 2.1 mo. payback 89% ROI
- #9 Assuming 3,000 ft of welding per month, 33% operating factor and $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings. $17,000 savings in 6 months 2 mo. payback 100% ROI
- #10 $30,000 savings in 6 months Current method: 228 ft2 per month SpinArc: 400 ft2 per month Both 75% OF $50/hr labor & overhead rate Does not include savings from reduced joint prep or electricity savings.
- #11 Assuming 4,000 ft of welding per month, 23% operating factor and $50/hr labor & overhead rate $169,000 savings in 6 months 9 days payback 1900% ROI Does not include savings from reduced joint prep or electricity savings.