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5 Welding Applications SpinArc Totally Transforms

Posted by Scott Funderburk on Feb 16, 2017 8:43:07 AM
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So you read about the SpinArc process. The benefits and ease of implementation are intriguing. But you only use certain welding applications, so is SpinArc designed for any of them?

Yes, they are! One of the great benefits of the SpinArc welding process is that the process can be used across a multitude of welding applications. Throughout the welding industry, there are ongoing technical challenges where this technology may be helpful, including in industry segments such as aerospace, automotive, heavy construction, pipe mills, pipeline construction, offshore structures, and shipbuilding.

The SpinArc process can transform any of the welding applications found in those segments. Below are 6 welding applications that the SpinArc process completely transforms when correctly implemented:

#1: Narrow Groove Weld

One application where this technology fits exceptionally well is in narrow groove welds. These types of weld joints are commonly used today in offshore and cross-country pipeline construction with mechanized welding systems. Other industries are also beginning to utilize narrow groove welds for increased productivity.

Quality is equally important for these applications. For example, in the building of subsea flowlines and steel catenary risers (SCRs), the flaw acceptance criteria for these welds is often less than a millimeter, and every weld is 100% inspected with automatic ultrasonic testing (AUT). This high-resolution inspection leaves no room for error.

Figure 1 shows a weld cross-section from an X65 grade pipe with an outside diameter of 10 inches (273 mm) and a wall thickness of 1.25 inches (30 mm). In this project, the focus was on fill and cap pass development using a 1.0 mm (0.040 in) ER80Ni-1 solid wire. For this case, the wire feed speed was 585 in/min (23 m/min), resulting in a deposition rate was 12 lbs/hr (5.5 kg/hr), and the travel speed was 19 in/min (48 cm/min).

Figure 2 ER80Ni solid wire.jpgFigure 1: X65 grade pipe weld

When 0.045 inch (1.1 mm) metal core electrodes are used in similar joint, the deposition rate increased to 15 lbs/hr (6.8 kg/hr) with a wire feed speed of 550 in/ min (14 m/min). The same wire feed speed is utilized throughout the weld, even in the overhead position. There was sound fusion with a consistent bead profile both into the previous pass as well as into the sidewall.

#2: Clad Overlay

Another application is weld overlay of corrosion resistant alloy (CRA) materials. There are numerous methods of overlaying, including submerged arc and electroslag welding. Both of these methods are limited to the flat position only, which requires the parts to be positioned and rotated while welding. These methods require expensive equipment, turning rolls, and manipulators. Another method used today is gas tungsten arc welding (GTAW), or TIG welding. TIG is known for its high quality welds, but it is extremely slow.

Weld overlay with corrosion resistant alloys, such as 625, is a common requirement in the oil and gas industry. For sour service environments, specifications typically require a maximum iron content of 10% on the weld overlay surface. With standard arc welding processes, achieving this requires multiple weld passes, and two or three weld layers are common. Using the SpinArc process, a consistent and shallow penetration is possible. This minimizes the amount of base material chemistry that is pulled into the weld puddle.

Additionally, the rotating arc flattens the weld bead and provides for a gradual taper at the weld toes even with alloys that are typically sluggish like 625 and other nickelbased alloys. This increases the quality and enables a stronger fusion between beads. SpinArc is a preferred alternative for either of these methods. It easily plugs into existing welding power sources found in all fabrication shops today. Figure 2 shows an example of a weld overlay with a 1.2 mm 625 metal core electrode. Solid wire 625 alloys (ERNiCrMo-3) can also be used with equally beneficial results.

Clad Overlay Image.jpgFigure 2: 625 Overlay weld

#3: Square Butt Joint

The process has been used to fabricate complete joint penetration groove welds made from one side with a square-edge butt joint. These weld joints require little to no beveling. Plates from 3/16 inches (4.8 mm) up to 2 inches (50 mm) are welded successfully within a 0 – 3 degree bevel prep.

Figure 3 shows an example of 3/16 in (4.8 mm) steel plate. In this case, the plates were fitted tight with no gap and no edge bevel. The process is able to achieve 30 in/min (76 cm/min) travel speed at 15 lbs/hr (6.8 kg/hr) deposition rate with a nice back bead profile and complete penetration in a single pass.

Square Butt Joint.jpgFigure 3: Steel plate weld 3/16 inch

#4: Dual Torch

Figure 4 is a 1/2 in (12 mm) thick complete penetration groove weld made from one side on
DH/EH36 plate with an 0.045 in E80C-Ni1 H4 metal-cored electrode, 90Ar/10CO2 and Miller’s Accupulse waveform. A 3/16 in (4.8 mm) gap with a square-edge butt joint and ceramic backing were used for this example. Two passes were used, both at 18.5 in/min (47 cm/min), which opens up the option to run dual torches, for a single run, two-pass weld.

Dual Torch.jpgFigure 4: Square Butt Joint welded from one side with two passes

#5: Fillet Welds

The torch can be used to produce fillet welds by hand, mechanized systems or robots. The spin diameter, speed and direction can be tailored to the specific weld requirements. With a tight spin diameter, high-speed fillet welds are possible. While increasing the spin diameter and speed can deliver large fillet welds with equal leg sizes.

Dual torches are used to produce a multiple-pass fillet weld in one run. The first torch, with a tighter rotation, hits the root and establishes a flat face for the second torch. The trailing torch has a much wider rotation, which nails the toes and finishes off the fillet weld with a flat face and smooth toes.

SpinArc_Distortion_Reduction_Final

 


Now that you’ve read what SpinArc is, how it works, and what it can do for you, I’m sure you’re ready to see it in action or figure out exactly how much it can save you from a time and money standpoint!

Download our Welding ROI Calculator and compare SpinArc against your current process, and see the difference for yourself!

If you're looking to see the SpinArc firsthand, contact one of our Sales Team members, and schedule a demo.

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