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spa welding systems gmbh

spa welding systems gmbh | industriestr. 29 | 82194 gröbenzell/munichphone +49 81 42/4 44 59 90 | fax +49 81 42/4 44 59 99 | [email protected] | www.spa-welding.com 2

welcome

Welding is the most important and versatile joining technique. In fields where highest qualitydemands are required, standard solutions are not sufficient anymore.

Especially in the field of pipeline and narrow gap welding spa welding systems gmbh madecustomer oriented developments and solutions to its business.

This solutions not only perform highest quality demands but also prolong the service live ofused tools and guarantee a fast and safe mechanical handling and therefore increaseproductivity.

Our predominantly international and also national customers in pipeline- , steel- , plant construction and automotive industry appreciate our quickness, flexibility and creativity inour MIG and SAW welding application spectrum.

Here our unique coated current contact tips and gas nozzles achieve extraordinary good economic and ecologic results. This effect is even increased when using our high temperaturestrong copper alloy DHCA.

For welding hard to access areas our specially developed narrow gap welding system will ease your work.

When welding pipelines you can use our high quality positioning bands (guide rings) which webuild for almost any existing automatic orbital welding system including our new designedlatch system.

A brand new and unique automatic orbital welding system with an excellent cost/performanceratio just competed our program line and will be launched to the market.

Further more we offer various products in the field of welding technology. The innovativepotential of spa welding systems is still growing.Combination of different materials and a lean structure ensures a fast solution of today'swelding problems.

Michael KettC.E.O.


spa welding systems gmbh | industriestr. 29 | 82194 gröbenzell/munichphone +49 81 42/4 44 59 90 | fax +49 81 42/4 44 59 99 | [email protected] | www.spa-welding.com 3

article list

The article lists will be ready for download on our homepage www.spa-welding.com after thefair trade SCHWEISSEN & SCHNEIDEN 2009.

We can also send you the requested article lists through our online request centre:www.spa-welding.com

contact datas

fon: +49/08142/4445990fax: +49/08142/4445999

spa welding systems gmbhIndustriestr. 2982194 Gröbenzell / MunichGermany

[email protected]

http://www.spa-welding.com




spa welding systems gmbh | industriestr. 29 | 82194 gröbenzell/munich

phone 0049 81 42/4 44 59 90 | fax 0049 81 42/4 44 59 99 | [email protected] | www.spa-welding.com 4

table of contents

automated orbital welding page 5 - 7

n positioning bands

n spare parts for orbital welding systems

DHCA current contact tips page 8

n MIG current contact tips

n SAW current contact tips

spa automatic welding torches page 9 - 10

n OT 500 WHD (for GMAX and FCAW)

n OT 500 W (for GMAX and FCAW)

narrow gap welding page 11 - 13

n Inner Shield System (for self shielded wire FCAW-ss)

n SPAce System (for MIG welding)

spa coatings page 14 - 17

n WBC coating

n boron nitride coating

n aluminum oxide coating

spa root purging system page 18 - 19




In the field of automated orbital welding spa welding systems gmbh offers a wide range of

products, such as:

n positioning bands/guide rings for almost all manufacturers

of automated orbital welding systems

n a various selection of spare parts for orbital welding systems such as drive- and guide

wheels, ball bearings, connectors, cable assemblies, etc...

n electronically and mechanically maintenance of orbital machines.

automated orbital welding

n positioning bands


positioning band





n positioning bands

spa welding systems gmbh offers positioning bands for following manufacturers of

orbital welding machines and UT devices:

n Veraweld/Vermaat - Netherlands

n PSI/Proteus - Italy

n CRC Eavens - USA

n RTD - Netherlands

n Comet - UK

n Polysoude - France

n Phoenix Gold - Netherlands

n Sonotron - Israel

n PipeCat/Bug o Systems - USA

All positioning bands can be made out of stainless-, spring- or DUPLEX steel. An especially

designed latch mechanism ensures an easy set-up of the band of only one operator.

The latches are partly designed to fit any radius/diameter which offers many advantages

when ordering spare parts.

The reliable workmanship of the bands meet the highest quality requirements.

positioning bands made by spa welding systems gmbh offer following advantages:

n reliable workmanship of high quality materials

n easy to mount due to special latch systems

n all length available within short time

n high durability of the product

n very good cost/performance ratio

n customer-oriented individual solutions

n special alloys and coatings possible

spa is in no way affiliated with above named companies. The parts advertised for sale are no

genuine parts, but may be parts made for and by spa welding systems gmbh. References to above

manufactures are for your convenience only!






spa welding systems gmbh also offers following spare parts for selected manufacturers of

automated orbital welding systems:

n drive wheels

n guide wheels

n bearings

n wheel sets/sizing beams

n cable assemblies/supply lines

n motors

n electrical connectors

n welding torches

n gas- and current contact tips

All spare parts in our program line meet the highest quality requirements and have

a good cost/performance ratio.

spare parts





DHCA current contact tips

n MIG current contact tips

n SAW current contact tips

In comparison to the rods for standard tips which are produced by a melting fusion process,

DHCA (Dispersion Hardened Copper Alloy) is based on PM technology. This composite material

is produced by a combination of milling and mechanical alloying. Copper powder together with

dispersoid forming agents are intensively milled.

Continuous breaking and cold welding of the powder particles lead to an intimate mixture of

the different components. Then a copper based composite material is created with a homoge-

nous distribution of ultra fine and thermal strong oxides and carbides. As a result a high elec-

trical and thermal conductivity as well as abrasion resistance is guaranteed.The consolidation

is done by cold working of the milled powder and hot extrusion of the billets into rods or

tubes. Using common processes this semi-finished rods or tubes will be deep injected into an

electrolyte copper jacket.

Now we have the feedstock for our contact tips, a hard and thermal resistant core (DHCA)

and a high thermal and electrical conductive jacket (ECu).

DHCA current contact tips offer following advantages:

n thermal strength up to 850°F

n approx. 3 times prolonged service life compared to CuCrZr tips

n highly wear and tear resistant (long hole bore)

n improved electrical conductivity due to an electrolyte copper jacket

n best mechanical strength due to DHCA core

All kinds of current contact tips can be made and supplied out of DHCA composite material.

The tips can be also supplied with our approved and unique current insulating and spatter

repelling WBC coating.

DHCA current contact tips




spa automatic welding torches

spa automatic welding torches are specially designed for use in automatic applications parti-

cularly in orbital welding processes using solid wire (GMAW) or flux cored wire (FCAW).

There are 2 different versions the OT500W and the OT500WHD.

Both are equipped with an axial slidable gas nozzle which assures a optimum accessibility and

shielding gas protection for various groove depth.

In combination with the special designed Spade Tips both torches can reach a gap depth up to

54mm and are suited for a perfect root weld quality.Because of their robust workmanship this

torches can be used either in onshore- or offshore applications.

spa automatic welding torches offers following advantages:

n axial slidable gas nozzle

n high service life due to robust design

n optimal torch cooling

n high duty cycle

n versatile applicable

spa automatic welding torches are suitable in a wide field of welding applications especially

in automatic orbital welding procedures using GMAW or FCAW welding processes.

Due to the robust design this torches are mainly used in the pipeline welding industry for

on- and offshore lines.

OT 500 WHD OT 500 W




spa automatic welding torches

n OT 500 WHD (for GMAX and FCAW)

n OT 500 W (for GMAX and FCAW)

spa automatic welding torches offers following advantages:

n axial slidable gas nozzle

n high service life due to robust design

n optimal torch cooling

n high duty cycle

n versatile applicable

spa automatic welding torches are equipped with an axial slidable gas nozzle assures an

optimum accessibility and an optimum welding seam protection.

In combination with the special designed narrow gap contact tip, called Spade Tip, both

torches can reach a gap depth up to 54mm.

Because of their robust workmanship this torches can be used either in offshore- or onshore

applications.

OT 500 WHD

OT 500 W





narrow gap welding

n Inner Shield System (for self shielded wire FCAW-ss)

n SPAce System (for MIG welding)

The narrow gap welding systems Inner Shield and SPAce have following advantages:

n optimal workpiece accessibility

n best view on weld seam

n highly flexible through two different welding systems (massiv wire welding + flux cored welding)

n no short circuits by best insulating components

n for groove depth up to 180mm (7.10'')

n cost effective priced due to modular system

The narrow gap welding systems Inner Shield and SPAce cover a wide operational area for

difficult to access welds. Through their easy handling and their quick exchangeable single

components a productive workflow is warranted.

Inner Shield System SPAce System




narrow gap welding

n Inner Shield narrow gap welding system

Our narrow gap system Inner Shield is specially designed for welding self shielded wire (FCAW-ss)

and available in 2 versions: Glimmer System and Metal System.

The Glimmer System consists of a contact tube with an integrated contact tip, made in one

piece. It is equipped with a high thermal resistant white boron nitride protection cap, spatter

repelling and current insulating. The contact tube is covered and insulating with a glimmer

jacket.

By contrast the Metal System has an exchangeable DHCA contact tip and is equipped with

a special grey boron nitride ceramic protection cap. This protection cap is highly current

insulating, thermal shock resistant and spatter repelling. To optimize the service live the

glimmer insulator is covered with a nickel plated copper jacket.

narrow gap welding system Inner Shield offers following advantages:

n optimal work piece accessibility

n best view on weld seam

n for groove depth 90mm (3.54") and 180mm (7.10")

n no short circuits possible

n great savings in filler material and labour

The narrow gap welding system Inner Shield is available in the length 90mm (3.54") and

180mm (7.10") and flexible applicable in rail joint welding, pipeline welding and repair work.

The Inner Shield system is designed for a fluxe cored wire electrode of ø 2.0mm.

In addition to that we also provide appropriate welding torches from the shelf.

Inner Shield narrow gap welding system




narrow gap welding

n SPAce narrow gap welding system

The SPAce narrow gap welding system is designed for MIG applications in difficult to access

areas. The system is also equipped with a protection cap made out of a high quality boron

nitride ceramic. This ceramic is current insulating, extreme heat and thermal shock resistant

and shows excellent spatter repelling characteristics.

The current contact tube and tip are coated with a special boron nitride based and heat

resistant coating which results in an excellent current insulation. Possibly short circuits are

virtually excluded. The slim gas nozzle, equipped with our approved spatter repelling WBC

coating ensures best work piece accessibility. The system is available for almost any welding

torch on the market.

The SPAce narrow gap welding system offers following advantages:

n improved weld seam visability due to a very slim design

n optimal root acquisition by aperture angel of less than 60°

n great savings in filler material

n increased service life due to optimal combination of basic materials

n no short circuits due to best insulating components

n no toxic and expensive releasing agents required

SPAce narrow gap welding systems are available for several different groove depth which offers

possibly MIG applications in almost any welding task. Available for groove depth of 60mm

(2.36"), 90mm (3.54"), 120mm (4.72") and 150mm (5.90").The standard system is designed

for a 1.2mm (.045") wire electrode, but there are also contact tips available for wire ø 0.8mm

(.030"), 1.0mm (.039") and 1.6mm (1/16").

In addition we also can supply appropriate welding torches from the shelf.

SPAce narrow gap welding system




spa coatings

n WBC coating


n aluminum oxide coating

spa coatings were made to optimize the welding process in general. They are used for current

contact tips, gas nozzles and machine parts which are exposed to high spatter impacts or

need current insulating characteristics. Coatings supplied by spa welding systems gmbh

increase the duration of the components and help to improve the welding process due to their

flexible applicable properties.

spa coatings offer following advantages:

n spatter repelling and current insulating coatings (or both in one) possible

n can be applied on any surface

n less downtime (automation)

n no anti stick sprays or pastes necessary

n no toxic vapours

n increased durability results in higher productivity

In principle spa coatings can be applied in various fields of the production process and

welding work shops. The current insulating and thermal resistance properties offer new

oppurtunities in welding processes in particular when using DHCA materials.

coating versions




spa coatings

n WBC coating

spatter repelling

It´s our standard coating especially in combination with our shielding gas nozzles.

This coating has extreme spatter repelling characteristics and stands for less cleaning

work and increased service life of the gas nozzle.

Thermal resistant up to 400°C.

spatter repelling and current insulating

Also a standard coating used especially in combination with our DHCA current

contact tips. This coating has very good spatter repelling and current insulating

characteristics.

It is perfect suitable for narrow gap welding application and spade tips to avoid short

circuits with the work piece or torch.

Thermal resistant up to 400°C.


n minimum cleaning work

n no releasing agents required

n coatings are suitable for all gas nozzles, contact tips and metals

n flexible applicable due to different properties

n no retooling problems

In general coatings provided by spa significantly reduce sticking of harmful welding spatters

which results in a reduce cleaning time interval. This increases the service life and durability

of the gas nozzles and current contact tips.

The current insulating and thermal resistance properties offer new opportunities in welding

processes in particular when using spa DHCA materials.




spa coatings



A standard coating in combination with our DHCA current contact tips.

This coating provides excellent current insulating characteristics and has good

spatter repelling properties.

Especially used for applications in automized orbital welding with narrow bevel angles

to avoid short circuits.

Thermal resistant up to 400°C















spa coatings

n aluminium oxide coating


It´s an excellent coating in combination with our DHCA current contact tips.

This coating is extremely hard and resistant. In addition it is highly current insulating

and spatter repelling.

Especially suitable for all SAW tips which are exposed to high temperatures.

Thermal resistant up to 1200°C















spa root purging system

The spa root purging system is designed to protect the inside of the pipe welding seams from

oxygen. Especially it is used when welding stainless or DUPLEX steel. Here the pipe will be

sealed with the spa root purging system amounting to the weld gap and purged with forming

gas. This ensures that the weld seam(root) will be protected from oxygen.

A set of spa root purging system consist of sealing discs made out of a high temperature

resistant silicone and aluminium supporting discs assuring a perfect stabilisation and sealing

of the silicon discs. Further the spa root purging system has a sintered brass gas diffuser

providing a homogenous gas flow.

In combination with a tackle the spa root purging system can be positioned and removed

properly and quickly in the pipe. At the other end of the system a small gas distributor

guarantees that gas can leak and the gas pressure in the chamber remains constant.

Also the weld seam is perfectly shielded against the atmosphere.

The connecting device between the sealing and supporting discs is available in a fixed or

flexible version for getting access to pipe elbows.


The spa root purging system offers following advantages:

n highly flexible for different pipe diameters and pipe elbows


n high durability by high quality of components

The spa root purging system is designed for purging pipes up to a diameter of 500mm (20").

The smallest pipe diameter you can purge is 50mm (2'').





The spa root purging system is perfectly applicable in the field of pipewelding - mainly

made out of VA and Duplex Steal. In general the welding process will be optimized and insures

a welding process stability.

The spa root purging system offers following advantages:

n ease of operation

n covers pipe diameters from 50mm (2") to 500mm (20")

n highly flexible for different pipe diameters and pipe elbows


n high durability by high quality of components

n quick installation and removal ensured

The spa root purging system is designed for purging pipes up to a diameter of 500mm (20").

The smallest pipe diameter you can purge is 50mm (2'').

To guarantee a perfect fitting of the system, the out diameter of the sealing discs shall be

10mm (0.39") and the supporting discs shall be 20mm (0.79") smaller than the pipe inside

diameter.

spa root purging system spa root purging system

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