SWRHyperFill 1Click image to enlargeNovarc claims its recently launched SWR+HyperFill is modernizing historic welding practices, allowing pipe fabrication shops to realize higher performance and productivity, while improving their bottom line.

 SWR+HyperFill was launched after extensive independent research on welding productivity, costs, quality and efficiencies, Novarc says. It adds that its research found that substantial productivity improvements in deposition rate, deposition efficiency, and duty cycle, compared to the baseline processes, were consistently achieved.

Essentially, Novarc’s SWR+HyperFill option expands the capabilities of the company’s collaborative Spool Welding Robot (SWR) designed to collaborate with operators to automate the pipe welding process.

SWR+HyperFill is a fully-integrated dual torch system that uses Lincoln Electric’s patented twin-wire GMAW solution, HyperFill, to maximize productivity and profitability allowing fabrication shops to expand the capabilities of the SWR. The system increases heavy fabrication productivity by increasing weld deposition rates while delivering excellent weld quality.

“We wouldn’t have been able to make the lead time on the current project we are doing without the SWR - we would have probably had to outsource some of the pipe fabrication,” says Paul Hebson, VP & General Manager at Vancouver Drydock

SWR+HyperFill uses the Lincoln STT GMAW process on the root, and twin wire (HyperFill) on fill and cap passes, and it can be used on carbon steel pressure pipes or vessels with 0.5” - 2” thickness and as low as 6” in diameter. The system also has the flexibility of using root to cap GMAW or seamlessly switching to FCAW or MCAW for the fill and cap passes.

“We were shocked to see that there was a 3X increase in productivity using the SWR. But we’re also very pleased at the high level of safety it provides to our workers,” says

Peter Tuck, Regional VP, Black & McDonald.

Here is a snapshot of SWR+HyperFill benefits for pipe shops, according to Novarc:

  • Higher deposition rates and efficiencies, reducing welding times and material handling costs compared to using the sub-arc process
  • Higher production rates (lb/hr) by streamlining and simplifying production, increasing efficiency and reducing costs
  • Excellent weld quality
  • Increase Factored Diameter Inches (FDI) to 350-500 per shift on carbon steel pipes
  • Meet ASME Section 1X and B31.3 WPS qualification requirements
  • Achieve high toughness test results down to -50 ℉ (-45℃)
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