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SpinArc® Welding Process Technology - Overview

The document outlines the Spinarc® productivity solution for welding, highlighting significant reductions in weld costs and increases in productivity across various applications and materials. It presents multiple case studies demonstrating improved efficiencies, reduced welding metal, and minimized distortion, with detailed specifications for different welding scenarios. The benefits of using Spinarc® include faster weld speeds, cost savings, and enhanced quality in various industries such as transportation, shipbuilding, and oil & gas.

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v Houston, Texas USA www.weldrevolution.com It’s all about productivity
https://youtu.be/z58texOgKdQ YouTube Channel https://www.youtube.com/user/weldrevolution/videos
How does it work? high speed rotation 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 go from this... to this!
Industry Segments Transportation Ship Building Pipeline Offshore Structural Oil & Gas Heavy Fabrication Power Generation
Weld Types & Materials Fillet Welds Groove Welds OverlayPlug Welds Steel Aluminum High Alloy Stainless Steel
v productivity case studies welding applications The savings presented are for illustration purposes only. They are examples of potential savings and include estimates of current costs, labor & overhead rates, etc.
SpinArc® Productivity Solution Reduced Bevel (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®
SpinArc® Productivity Solution Reduced Bevel (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 $10 $15 $20 $25 $30 $35 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
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 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®
SpinArc® Productivity 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 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®
SpinArc® Productivity 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 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®
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®
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®
SpinArc® Productivity Solution Sample 7 625 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®
SpinArc® Productivity Solution Sample 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®
Clad Overlay • shallow, consistent penetration • flat bead profile • ultralow iron content (2% - 5% with single layer) • Solid or metal core wires • CV or Pulse modes • Deposition rates 5 x GTAW, and in the SAW range, 12-15 lbs/hr (5–7 kg/hr) • Can be utilized out of position 1.8mm Single Layer Deposit
0.00 5.00 10.00 15.00 20.00 25.00 0 0.5 1 1.5 2 2.5 %Fe Distance from Fusion Line (mm) % Fe, .045" ERNiCrMo-3 (625) Clad Overlay, 1G 1G Position, single weld layers, 1/4" A36 0.045" ERNiCrMo-3 solid wire GMAW-P, 100% Ar 500 ipm WFS, 17.3 ipm TS 0.38" (9.65 mm) Spin Dia., Spin Setting #8, 1800 RPM % Fe, SEM EDS calibrated verses actual wire composition 625 Clad 1G Position
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2 %Fe Distance from Fusion Line (mm) % Fe, .035" ERNiCrMo-3 (625) Clad Overlay, 3G Vertical Down 3G Position, single weld layer, 3/4" A36 0.035" ERNiCrMo-3 solid wire GMAW-P, 100% Ar 675 ipm WFS, 16 ipm TS, Spin Setting #8, 1300 RPM % Fe, SEM EDS calibrated verses actual wire composition 625 Clad 3G Vertical Down
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 • .045” (1.1 mm) E70C-6 FabCOR 86R • TS: 15.4 ipm (38 cm/min) • WFS: 600 ipm (15 m/min) • DR: 15.8 lbs/hr (7 kg/hr) • Spin: 3 @ 3,200 RPM • Square butt joint • 4 passes 3/4” (19 mm) 5/16” (8 mm)
1G Plate
Pass 1 Pass 2 WFS 550 ipm 625 ipm (14 m/min) (16 m/min) Spin Speed (rpm) 1,500 3,000 Spin Dia. (mm) 3.5 4.8 ½” (12 mm) Single Sided • EH/DH 36 ship building grade material • GMAW-P (Miller AccuPulse) • 0.045” (1.1 mm) E80C-Ni1 H4, 90Ar/10CO2 • Square butt, 3/16” gap (4.7 mm) • Full Pen/One-sided w/ ceramic backing • 7/8” (22 mm) CTWD • Travel Speed: 18.5 in/min (47 cm/min)
• All Weld Metal – Yield: 95.5 ksi – Tensile: 114 ksi – Elongation: 29.7% • Cross Weld Tensile – Ductile Fracture in Base Metal – Tensile: 82 ksi • CVN (-29 C) – Transverse Weld Metal: 25 ft-lb avg. – HAZ: 74.3 ft-lb avg. • Side Bends Passed ½” (12 mm) Single Sided
100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0 300.0 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 VickersMicrohardness(1000gload) Distance from first indentation (inch) Cap Middle Root Microhardness Cap Middle Root
¼” (6 mm) Single Pass • Full Pen/One-sided with ceramic backing • .045” (1.1 mm) E80C-Ni1 H4 metal core • 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
Microhardness Cap Middle Root 100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0 300.0 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 0.70 VickersMicrohardness(1000gload) Distance from from first indentation (inch) Cap Middle Root
Distortion Comparison ¼” (6 mm) Single Pass Reduced Distortion on high strength 4130SpinArc® Conventional SpinArc® Longitudinal (4” from plate CL) 0.040” (1 mm) < 0.020” (0.5 mm) Angular (4” from weld CL) 0.140” (3.6 mm) < 0.010” (0.3 mm)
One-Sided, 30° Single-Vee • 3/4” (19 mm) mild steel • 30° included bevel • Full pen, 1 side • 4 passes • .052” (1.3 mm) metal core • GMAW-P (root), CV (fills & cap) • 80/20 Ar/CO2 • 13.5 lbs/hr (6 kg/hr)
One Sided, 15° Single Bevel • 3/4” (19 mm) mild steel • 15° Single Bevel • Full Penetration, 1 side • .052” (1.3 mm) metal cored • GMAW-P (root, 2G) • CV (2 fills & 1 cap, 1G) • TS: 18 IPM (46 cm/min) • WFS: 350 IPM (9 m/min) • DR: 12 lbs/hr (5.4 kg/hr)
Column Splice, 15° Single Bevel Problem: • long weld time • Typically, 35o included angle 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
v Guidelines SpinArc® Welding
Groove Designs Thickness Groove Width Backing or Root Land 1/2“ – 1 ¼” (12-32 mm) 3/8” (10 mm) Needed 3/8” – 1/2” (10-12 mm) 3/16” – 3/8” (5-10 mm) Needed 1/4” – 3/8” (6-10 mm) 3/32” – 1/8” (2-3 mm) Needed 1/8” – 1/4” (2-6 mm) 1/16” – 3/32” (1.6-2 mm) Optional 1/16” – 1/4” (1.6-6 mm) 0” Optional Welding in Groove Welding on top of Groove
Groove Designs for T > 1 ¼” (32 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 SpinDiameterSetting 1 2 3 4 5 6 7 8 1000 2000 3000 4000 5000 Clad Overlay Pipe Narrow Groove Sheet & Plate up to ¼” Plate Square Groove Butt Fillets Spin Speed, RPM
0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 1 2 3 4 5 6 7 8 SpinSpeed(rpm) Spin Diameter (Crank Setting) Recommended Operating Range Recommended Operating Range Recommended Operating Range Crank Setting Max RPM 1 5500 2 5500 3 5500 4 4500 5 3500 6 2750 7 2000 8 1200 Flexure
Productivity STUDIES Conventional SpinArc®
¾” (19 mm) plate example: 52% cost reduction 0.4 month payback period
v MA-400 SpinArc® System Mechanized SpinArc® System plug & play for an instant upgrade
SpinArc® SYSTEM Control Box Control Cable Aux Arc On (optional) Trigger SpinArc® Torch
MA-400 SpinArc® System System includes… SpinArc® torch and cable, control box, & control cables 400 Amp, 100% duty cycle, air cooled 0.035 – 1/16” (0.9 – 1.6 mm) wire 3 – 20 ft. (1.8 – 6.1 m) cables GMAW, GMAW-P, FCAW Rated to IEC/EN 60974-7 1.75” (44 mm) 12” (300 mm)
Control Box Manual or remote mode CW or CCW spin direction 110-240 VAC, 50/60 Hz Spin Delay (0-5 sec) 200 – 5,500 rpm CSA, RoHS Compliant
Plug ‘n Play ALL FEEDERS
Adjustable SPIN DIAMETER 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 – Infinitely adjustable weld parameters – Fully integrated with Bug-O mechanized welding systems
Setup Video https://youtu.be/rih-Z4hyeOw
Pipe Welding BUG & BAND
Flexible MECHANIZATION
Semi-Automatic HAND WELDING KIT
Robotic INTEGRATION
less weld metal excellent toe wetting smooth bead profile control bead size/penetration fast travel speed perfect side wall fusion consistent HAZ cleaner weld by puddle stirring it’s all about PRODUCTIVITY + QUALITY
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.

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SpinArc® Welding Process Technology - Overview

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    How does itwork? high speed rotation centrifugal force all position welding high deposition
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    40% Increased Productivity gofrom this... to this!
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    Industry Segments Transportation ShipBuilding Pipeline Offshore Structural Oil & Gas Heavy Fabrication Power Generation
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    Weld Types &Materials Fillet Welds Groove Welds OverlayPlug Welds Steel Aluminum High Alloy Stainless Steel
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    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.
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    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®
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    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 $10 $15 $20 $25 $30 $35 WeldCost($) Total Cost Per Foot of Weld Current SpinArc®
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    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®
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    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®
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    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®
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    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®
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    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®
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    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®
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    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®
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    Clad Overlay • shallow,consistent penetration • flat bead profile • ultralow iron content (2% - 5% with single layer) • Solid or metal core wires • CV or Pulse modes • Deposition rates 5 x GTAW, and in the SAW range, 12-15 lbs/hr (5–7 kg/hr) • Can be utilized out of position 1.8mm Single Layer Deposit
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    0.00 5.00 10.00 15.00 20.00 25.00 0 0.5 11.5 2 2.5 %Fe Distance from Fusion Line (mm) % Fe, .045" ERNiCrMo-3 (625) Clad Overlay, 1G 1G Position, single weld layers, 1/4" A36 0.045" ERNiCrMo-3 solid wire GMAW-P, 100% Ar 500 ipm WFS, 17.3 ipm TS 0.38" (9.65 mm) Spin Dia., Spin Setting #8, 1800 RPM % Fe, SEM EDS calibrated verses actual wire composition 625 Clad 1G Position
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    0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 0 0.2 0.40.6 0.8 1 1.2 1.4 1.6 1.8 2 %Fe Distance from Fusion Line (mm) % Fe, .035" ERNiCrMo-3 (625) Clad Overlay, 3G Vertical Down 3G Position, single weld layer, 3/4" A36 0.035" ERNiCrMo-3 solid wire GMAW-P, 100% Ar 675 ipm WFS, 16 ipm TS, Spin Setting #8, 1300 RPM % Fe, SEM EDS calibrated verses actual wire composition 625 Clad 3G Vertical Down
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    Clad Overlay VerticalDown https://youtu.be/2ypRMYEdMXE
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    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
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    5G Pipe WeldingVideo https://youtu.be/lQ_t47hW2Rg
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    1G Plate • .045”(1.1 mm) E70C-6 FabCOR 86R • TS: 15.4 ipm (38 cm/min) • WFS: 600 ipm (15 m/min) • DR: 15.8 lbs/hr (7 kg/hr) • Spin: 3 @ 3,200 RPM • Square butt joint • 4 passes 3/4” (19 mm) 5/16” (8 mm)
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    Pass 1 Pass2 WFS 550 ipm 625 ipm (14 m/min) (16 m/min) Spin Speed (rpm) 1,500 3,000 Spin Dia. (mm) 3.5 4.8 ½” (12 mm) Single Sided • EH/DH 36 ship building grade material • GMAW-P (Miller AccuPulse) • 0.045” (1.1 mm) E80C-Ni1 H4, 90Ar/10CO2 • Square butt, 3/16” gap (4.7 mm) • Full Pen/One-sided w/ ceramic backing • 7/8” (22 mm) CTWD • Travel Speed: 18.5 in/min (47 cm/min)
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    • All WeldMetal – Yield: 95.5 ksi – Tensile: 114 ksi – Elongation: 29.7% • Cross Weld Tensile – Ductile Fracture in Base Metal – Tensile: 82 ksi • CVN (-29 C) – Transverse Weld Metal: 25 ft-lb avg. – HAZ: 74.3 ft-lb avg. • Side Bends Passed ½” (12 mm) Single Sided
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    ¼” (6 mm) SinglePass • Full Pen/One-sided with ceramic backing • .045” (1.1 mm) E80C-Ni1 H4 metal core • 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
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    Distortion Comparison ¼” (6mm) Single Pass Reduced Distortion on high strength 4130SpinArc® Conventional SpinArc® Longitudinal (4” from plate CL) 0.040” (1 mm) < 0.020” (0.5 mm) Angular (4” from weld CL) 0.140” (3.6 mm) < 0.010” (0.3 mm)
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    One-Sided, 30° Single-Vee •3/4” (19 mm) mild steel • 30° included bevel • Full pen, 1 side • 4 passes • .052” (1.3 mm) metal core • GMAW-P (root), CV (fills & cap) • 80/20 Ar/CO2 • 13.5 lbs/hr (6 kg/hr)
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    One Sided, 15°Single Bevel • 3/4” (19 mm) mild steel • 15° Single Bevel • Full Penetration, 1 side • .052” (1.3 mm) metal cored • GMAW-P (root, 2G) • CV (2 fills & 1 cap, 1G) • TS: 18 IPM (46 cm/min) • WFS: 350 IPM (9 m/min) • DR: 12 lbs/hr (5.4 kg/hr)
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    Column Splice, 15°Single Bevel Problem: • long weld time • Typically, 35o included angle 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
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    15° Beam-to-Column Problem: • Fusionto 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
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    Groove Designs Thickness GrooveWidth Backing or Root Land 1/2“ – 1 ¼” (12-32 mm) 3/8” (10 mm) Needed 3/8” – 1/2” (10-12 mm) 3/16” – 3/8” (5-10 mm) Needed 1/4” – 3/8” (6-10 mm) 3/32” – 1/8” (2-3 mm) Needed 1/8” – 1/4” (2-6 mm) 1/16” – 3/32” (1.6-2 mm) Optional 1/16” – 1/4” (1.6-6 mm) 0” Optional Welding in Groove Welding on top of Groove
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    Groove Designs forT > 1 ¼” (32 mm) Example: 35% efficiency improvement $55.00/ft. ($17/m) cost reduction x 1,500 ft. (457 m) per month =$75,000/month savings
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    Typical Operating Ranges- Steel SpinDiameterSetting 1 2 3 4 5 6 7 8 1000 2000 3000 4000 5000 Clad Overlay Pipe Narrow Groove Sheet & Plate up to ¼” Plate Square Groove Butt Fillets Spin Speed, RPM
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    0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500 6000 1 2 34 5 6 7 8 SpinSpeed(rpm) Spin Diameter (Crank Setting) Recommended Operating Range Recommended Operating Range Recommended Operating Range Crank Setting Max RPM 1 5500 2 5500 3 5500 4 4500 5 3500 6 2750 7 2000 8 1200 Flexure
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    ¾” (19 mm)plate example: 52% cost reduction 0.4 month payback period
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    v MA-400 SpinArc® System MechanizedSpinArc® System plug & play for an instant upgrade
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    SpinArc® SYSTEM Control Box Control Cable AuxArc On (optional) Trigger SpinArc® Torch
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    MA-400 SpinArc® System System includes… SpinArc®torch and cable, control box, & control cables 400 Amp, 100% duty cycle, air cooled 0.035 – 1/16” (0.9 – 1.6 mm) wire 3 – 20 ft. (1.8 – 6.1 m) cables GMAW, GMAW-P, FCAW Rated to IEC/EN 60974-7 1.75” (44 mm) 12” (300 mm)
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    Control Box Manual orremote mode CW or CCW spin direction 110-240 VAC, 50/60 Hz Spin Delay (0-5 sec) 200 – 5,500 rpm CSA, RoHS Compliant
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    Spin Speed andDiameter Affect of Spin Speed (RPM) on Spin Diameter: https://youtu.be/23r348Rej4g
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    Piper Plus – IntegratedSpinArc® controls – Inclinometer – Infinitely adjustable weld parameters – Fully integrated with Bug-O mechanized welding systems
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    less weld metal excellenttoe wetting smooth bead profile control bead size/penetration fast travel speed perfect side wall fusion consistent HAZ cleaner weld by puddle stirring it’s all about PRODUCTIVITY + QUALITY
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    v Weld Revolution 19511 WiedRoad Spring, TX 77388 USA 832-585-1244 sales@weldrevolution.com www.weldrevolution.com
  • 60.
    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

  • #12 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.
  • #13 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%
  • #14 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
  • #15 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
  • #16 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
  • #17 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
  • #18 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
  • #19  $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.
  • #20 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.
  • #27 ERIC
  • #29 SCOTT
  • #31 Flat, ½” Single Sided, Two Pass
  • #35 ERIC
  • #36 ERIC
  • #39 AARON
  • #40 AARON
  • #41 AARON
  • #42 AARON
  • #46 SCOTT