v

It’s all about productivity

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?

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 Plug Welds Overlay

Steel Aluminum High Alloy Stainless Steel

 welding applications

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

• 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
Weld Cost ($)

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

• .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
Weld Cost ($)

Total Cost Per Foot of Weld Why choose SpinArc®?

Current
$32.84 • 60% weld cost reduction
SpinArc®
• 50% productivity increase
• 40% less weld metal
$12.54
• Reduced distortion
• No slag removal

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 ($)

Total Cost Per Foot of Weld

Why choose SpinArc®?
40
Current • 60% weld cost reduction
35

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 ($)

Why choose SpinArc®?

Total Cost Per Foot of Weld
• 55% weld cost reduction
Current
SpinArc® • 60% productivity increase
• 50% less weld metal
$1.42
• Reduced distortion

$0.59
• No slag removal
• No beveling

SpinArc® is 2.5x faster

 SpinArc® Productivity Sample 5

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 ($)

Why choose SpinArc®?

Total Cost Per Foot of Weld
• 63% weld cost reduction
Current
SpinArc® • 70% productivity increase
• 25% less weld metal
$6.98 • Reduced distortion
• No slag removal
$2.58
• No beveling

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 ($)

Total Cost Per Foot of Weld Why choose SpinArc®?

Current
• 25% weld cost reduction
SpinArc®
• 30% productivity increase
$1.70 • Consistent, flat bead profile
$1.29
• Good tie-in to each plate and root

SpinArc® is 1.4x faster

 SpinArc® Productivity Sample 6b

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 ($)

Total Cost Per Foot of Weld Why choose SpinArc®?

Current
SpinArc®
• 25% weld cost reduction
• 30% productivity increase
$5.59 • Large, flat single-pass fillet
$4.16
• Good tie-in to each plate and root
• Reduced distortion

SpinArc® is 1.4x faster

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
Labor Cost ($)

Why choose SpinArc®?

Labor Cost Per Sq. Ft of Overlay
50 • 50% welding labor savings
45 Current
40 SpinArc®
• 100% productivity increase
35
• 50% less weld metal
30
25 $46.67 • Reduced distortion
20
15 • Consistently achieve <10% Fe in 1 layer
10 $20.00
5
0

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 ($)

Why choose SpinArc®?

Total Cost Per Foot of Weld
1 • 65% weld cost reduction
Current
SpinArc®
• 65% productivity increase
1 • 20% less weld metal
• No slag removal
$11.08 • No beveling
• Reduced distortion
$3.65

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)

• .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) 3/4”
(19 mm)
• Spin: 3 @ 3,200 RPM
• Square butt joint
• 4 passes
1G Plate
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)

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
• 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
 Cap

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® Reduced Distortion on high strength

4130
Conventional SpinArc®

Longitudinal 0.040” < 0.020”

(4” from plate CL) (1 mm) (0.5 mm)

Angular 0.140” < 0.010”

(4” from weld CL) (3.6 mm) (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
 Procedure Qualification
R&D Project Objectives:

• Qualify ¾” thick weld to

CSA W47.1 and ASME IX
codes

• Compare a SpinArc® weld

against a CSA prequalified
Submerged Arc Weld
(SAW) joint.
Side Bend Tests

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

All dimensions in Inches

Weld Profile Comparisons

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

SAW SpinArc® Total Cost

Cross Sectional Area (in2) 0.3794 0.1875
$14.30
Wire Cost $1.30 $0.76
Arc-On Time (minutes) 6.24 4.56
$8.36
Shielding Gas Cost/Flux Cost $1.82 $0.36
Total Production Time (minutes) 8.97 5.76
SAW SpinArc®
Total Cost $14.30 $8.36
40% savings
*All costs based on the consumables used in this research project*

**All times and cost reflect a twelve inch long joint**

Guidelines
SpinArc® Welding

v
Groove Designs Backing or
Thickness Groove Width
Root Land

1/2“ – 1 ¼” 3/8”
Needed
(12-32 mm) (10 mm)

3/8” – 1/2” 3/16” – 3/8” Needed

(10-12 mm) (5-10 mm)

Welding in Groove
1/4” – 3/8” 3/32” – 1/8”
Needed
(6-10 mm) (2-3 mm)

1/8” – 1/4” 1/16” – 3/32”

Welding on top (2-6 mm) (1.6-2 mm) Optional
of Groove
1/16” – 1/4”
(1.6-6 mm) 0” Optional
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
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

1000 2000 3000 4000 5000

Spin Speed, RPM

 Recommended Operating Range
6000
Spin Speed (rpm)

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

Aux Arc On (optional)

Trigger

Control Cable

SpinArc® Torch
 MA-400
SpinArc® System

System includes…
SpinArc® torch and cable, control box, & control
1.75” (44 mm)
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
12”
(300 mm)
Rated to IEC/EN 60974-7
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

IP51
 Product Length, L
Number

Weld Cable Length MA-400-3m

MA-400-4m
3 m (10 ft.)
4 m (13 ft.)
MA-400-5m 5 m (16 ft.)
MA-400-6 6 ft. (1.8 m)
MA-400-10 10 ft. (3.0 m)
MA-400-15 15 ft. (4.6 m)
MA-400-XX 3 – 20 ft. (.9 – 6.1m)
Even increments of 1
ft.
L
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
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.