Red-D-Arc sparks success: submerged-arc welding revs up production of thin vessels

Overlay welding hard surfacing of steel rolls by the submerged-arc welding process

Red-D-Arc Welderentals is trusted by manufacturers and other businesses around the world for its portfolio of welding solutions, generators, dry-ice blasting machines, and other industrial equipment. This wide selection has satisfied many customers, earning the company a long history of client success stories to back up its international credibility.

One such happy customer, located in Charlotte, N.C., was a metal-fabrication company that needed help with mass production of small-inner-diameter vessels.

Productivity increased by 2½ times

The company had received an order for 300 of these vessels for titanium moulds. It was using flux-cored arc welding and back-gouging the insides and outsides of the vessels to achieve full penetration, but this resulted in only two vessels produced per hour with two welders, on average. For a quicker, more efficient means of making these vessels, the company turned to the Red-D-Arc team.

The customer bought a turnkey submerged-arc system after consulting with Red-D-Arc. This custom-designed system came complete with a sub-arc welding head for small inner diameters mounted on a nine-by-nine-foot manipulator, flux recovery system, NA5R automatic wire feeder, DC600 multi-process welder, and five-ton turning rolls. Also included in the system: a laser and camera for exact control and monitoring of the welding process.

The new welding system boosted productivity by 250 per cent, enabling manufacture of five cans an hour with ½ the labour expense. In addition, the system increased workplace safety in several ways: it eliminated back gouging, which lowered the risk of fire; turning rolls replaced manual rotation of the vessels on tables; and the welders no longer had to work inside the confined spaces of the vessels.

The customer was so happy with the result that a decision was made to buy two more of these Red-D-Arc turnkey submerged-arc systems for future projects. This outcome is typical for submerged-arc welding, which can increase the quality and efficiency of many industrial welding applications, no matter the complexity or size. Red-D-Arc Welderentals offers all the solutions, know-how, and experience required to offer a submerged-arc welding system – for sale, rental, or lease – to meet any requirements.

For more information, contact Red-D-Arc.

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