productivity case studies

Transcription

1 welding applications v productivity case studies The savings presented are for illustration purposes only. They are examples of potential savings and include estimates of current costs, labor & overhead rates, etc.

2 Productivity Solution Sample 1 Reduced Bevel (60 à 30 o ) Changed.045 FCAW-G to.052 MC SpinArc 1G ceramic backing 3/4 T (19 mm).052 ER70C-6, 90/10 Ar/CO 2 30 o included angle 1/8 (3.2 mm) root opening 16 lbs/hr (7.3 kg/kr) 15 ipm (38 cm/min) travel speed $25.60 $7.75 SpinArc is 3x faster 70% weld cost reduction 75% productivity increase 40% less weld metal No slag removal

3 Productivity Solution Sample 2 Reduced Bevel (37.5 à 20 o ).045 FCAW-G to 1/16 solid wire SpinArc 1G ceramic backing 1 T (25 mm) 1/16 ER70C-6, 90/10 Ar/CO 2 20 o included angle 1/8 (3.2 mm) root opening 12 lbs/hr (5.4 kg/hr) 17 ipm (43 cm/min) travel speed $32.84 $12.54 SpinArc is 2x faster 60% weld cost reduction 50% productivity increase 40% less weld metal No slag removal

4 Productivity Solution Square Butt Joint 60 o bevel to square butt with SpinArc 1G steel backing 1.25 T (32 mm) 1/16 ER70S-6, 90/10 Ar/CO 2 3/8 (9.5 mm) groove width 14 lbs/hr (6.3 kg/hr) 13 ipm (33 cm/min) travel speed Sample $34.55 $13.33 SpinArc is 2.5x faster 60% weld cost reduction 60% productivity increase 60% less weld metal No slag removal No beveling

5 Productivity Solution Sample 4 Square Butt Joint 30 o 2-sided weld to sq. butt w/ SpinArc 2G, no backing 0.25 T (6.3 mm) ER70S-6, 80/20 Ar/CO 2 1/16 (1.6 mm) root opening 10 lbs/hr (4.6 kg/hr) 22 ipm (56 cm/min) travel speed $1.42 $0.59 SpinArc is 2.5x faster 55% weld cost reduction 60% productivity increase 50% less weld metal No slag removal No beveling

6 Productivity Solution Sample 5 Square Butt Joint 60 o bevel to square butt with SpinArc 1G, ceramic backing 3/8 T (9.5 mm).045 ER70C-6, 90/10 Ar/CO 2 1/4 (6.3 mm) root opening 16 lbs/hr (4.6 kg/hr) 21 ipm (53 cm/min) travel speed $6.98 $2.58 SpinArc is 3x faster 63% weld cost reduction 70% productivity increase 25% less weld metal No slag removal No beveling

7 Productivity Solution Sample 6a ¼ Fast Fillet Weld 29 to 40 in/min travel speed with SpinArc 2F 3/8 T (9.5 mm).045 ER70C-6, 80/20 Ar/CO lbs/hr (7.1 kg/hr) 40 ipm (102 cm/min) travel speed $1.70 $ % weld cost reduction 30% productivity increase Consistent, flat bead profile Good tie-in to each plate and root SpinArc is 1.4x faster

8 Productivity Solution Sample 6b 3/8 Big, Single-Pass Fillet Weld 2 passes reduced to 1 pass with SpinArc 2F 3/8 T (9.5 mm).1/16 ER70C-6, 80/20 Ar/CO lbs/hr (5.8 kg/hr) 11.5 ipm (29.2 cm/min) travel speed $5.59 $4.16 SpinArc is 1.4x faster 25% weld cost reduction 30% productivity increase Large, flat single-pass fillet Good tie-in to each plate and root

9 Productivity Solution 625 Clad Overlay 2 passes reduced to 1 pass with SpinArc 1/8 bead thickness (3.2 mm).045 ERNiCrMo-3, 100% Ar 14.5 lbs/hr (6.6 kg/hr) 11 ipm (28 cm/min) travel speed 1 bead width 3.3 ft 2 /hour coverage Sample 7 Labor Cost ($) Labor Cost Per Sq. Ft of Overlay $46.67 $2 50% welding labor savings 100% productivity increase 50% less weld metal Consistently achieve <10% Fe in 1 layer SpinArc is 2x faster

10 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 ER70S-6, 82/10/8 Ar/He/CO lbs/hr (4.9 kg/hr) 18 ipm (46 cm/min) travel speed $11.08 $ % weld cost reduction 65% productivity increase 20% less weld metal No slag removal No beveling SpinArc is 3x faster

11 For more information Weld Revolution LLC Wied Road Spring, TX USA

12 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.