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Houston, Texas USAwww.weldrevolution.com
It’s all about productivity
https://youtu.be/z58texOgKdQ
YouTube Channelhttps://www.youtube.com/user/weldrevolution/videos
How does it work?
high speed rotation
centrifugal force all position weldinghigh deposition
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 i l lustration purposes only. They are examples of potential savings and include estimates of current costs, labor & overhead rates, etc.
SpinArc® Productivity SolutionReduced 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 faster0
5
10
15
20
25
30
$25.60
$7.75
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity SolutionReduced 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 $-
$5
$10
$15
$20
$25
$30
$35 $32.84
$12.54
Total Cost Per Foot of Weld
CurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity SolutionSquare 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 faster05
10152025303540
$34.55
$13.33
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity SolutionSquare 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 faster0.000.200.400.600.801.001.201.401.60
$1.42
$0.59
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity SolutionSquare 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 faster0.001.002.003.004.005.006.007.008.00
$6.98
$2.58
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity Solution¼” 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 faster0.000.200.400.600.801.001.201.401.601.80
$1.70
$1.29
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity Solution3/8” 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 0.00
1.00
2.00
3.00
4.00
5.00
6.00
$5.59
$4.16
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
SpinArc® Productivity Solution Sample 7625 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 05
101520253035404550
$46.67
$20.00
Labor Cost Per Sq. Ft of OverlayCurrentSpinArc®
Labo
r Co
st (
$)
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
0.00
2.00
4.00
6.00
8.00
10.00
12.00
$11.08
$3.65
Total Cost Per Foot of WeldCurrentSpinArc®
Wel
d Co
st (
$)
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
625 Clad1G Position
625 Clad3G 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 2WFS 550 ipm 625 ipm(14 m/min) (16 m/min)Spin Speed (rpm) 1,500 3,000Spin 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
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
100.0
120.0
140.0
160.0
180.0
200.0
220.0
240.0
260.0
280.0
300.0
Cap
Middle
Root
Distance from first indentation (inch)
Vick
ers M
icroh
ardn
ess (
1000
g lo
ad)
MicrohardnessCap
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
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
100.0
120.0
140.0
160.0
180.0
200.0
220.0
240.0
260.0
280.0
300.0
Cap
Middle
Root
Distance from from first indentation (inch)
Vick
ers M
icroh
ardn
ess (
1000
g lo
ad)
Distortion Comparison ¼” (6 mm) Single Pass
Reduced Distortion on high strength 4130
SpinArc®
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 BevelProblem:• 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-ColumnProblem:• 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
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Guidelines SpinArc® Welding
Groove DesignsThickness 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 reductionx 1,500 ft. (457 m) per month =$75,000/month savings
Typical Operating Ranges - Steel Sp
in D
iam
eter
Setti
ng
1
23
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
1 2 3 4 5 6 7 80
500
1000
1500
2000
2500
3000
3500
4000
4500
5000
5500
6000Recommended Operating Range
Spin Diameter (Crank Setting)
Spin
Spe
ed (r
pm)
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 reduction0.4 month payback period
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MA-400 SpinArc® System Mechanized SpinArc® System
plug & p lay for an insta nt upg ra de
SpinArc®
SYSTEMControl 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 cooled0.035 – 1/16” (0.9 – 1.6 mm) wire
3 – 20 ft. (1.8 – 6.1 m) cablesGMAW, 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 PlayALL FEEDERS
AdjustableSPIN DIAMETER
Spin Diameter Settings (1-8)
Spin Speed and DiameterAffect 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
Pipe Welding BUG & BAND
Flexible MECHANIZATION
Semi-Automatic HAND WELDING KIT
RoboticINTEGRATION
less weld metalexcellent toe wetting
smooth bead profilecontrol bead
size/penetration
fast travel speedperfect side wall fusion
consistent HAZcleaner weld by puddle stirring
it’s all aboutPRODUCTIVITY +
QUALITY
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Weld Revolution19511 Wied Road
Spring, TX 77388 USA832-585-1244
sales@weldrevolution.comwww.weldrevolution.com
Customer Assistance PolicyWeld 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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