spinarc® productivity case studies

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

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$25.60

$7.75

Total Cost Per Foot of WeldCurrentSpinArc®

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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 faster0

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35 $32.84

$12.54


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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


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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


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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


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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


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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

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$5.59

$4.16


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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®

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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

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$11.08

$3.65


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For more informationWeld Revolution LLC19511 Wied RoadSpring, TX 77388 [email protected]

mailto:[email protected]

http://www.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.

spinarc® productivity case studies

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