TIP TIG Page 2

TIP TIG IS A LOGICAL PROCESS SELECTION FOR WELD
AUTOMATION ON CRITICAL AND ALLOY APPLICATIONS:



Have you ever wondered why you see so few robots successfully using the
regular Hot / Cold Wire TIG process? Have you ever wondered why the
Hot / Cold Wire feed rates are so low with automated orbital pipe welds?

Hot Wire current when added to the regular Hot Wire process provides a slight increase in TIG weld energy, however moderate current "all position" automated hot / cold wire welds will have a built in sensitivity to weld wire input (creating wire feed restrictions) and the Hot wire process will on many welds have a high degree of sensitivity to the variables that influence the weld.

WITH TIP TIG THE COMBINATION OF AN "AGITATED WELD WITH THE ADDITION OF THE HOT WIRE CURRENT" AND THE UNIQUE TORCH DRAMATICALLY CHANGE THE TIG WELD DYNAMICS PROVIDING MANY MANUAL / AUTOMATED WELD AND CLAD BENEFITS SUCH AS REDUCING THE SENSITIVITY TO THE WELD RECIEVING WELD WIRE, (INCREASING PRODUCTIVITY) PROVIDING SUPERIOR WELD QUALITY AND WITH WELD AUTOMATION "DRAMATICALLY REDUCING WELD DOWN TIME".

ATTAINING FIRST TIME OPTIMUM "CLAD" WELD QUALITY. When cladding is required the weld shop has many process options, however when "defect free" clad weld quality is required there are few cost effective process options.

Pulsed MIG is fine for external boiler water wall clad welds in which the NDT weld quality criteria is "visual and chemistry" however when the cladding is subject to machining, X-Ray or UT examination the pulsed MIG process will likely reveal the application is subject to occasional lack of weld fusion, porosity, small pore inclusions and inconsistent weld ties-ins. Pulsed MIG will also frequently cause weld heat issues.

MIG Short Circuit (SC) is frequently used for clad applications, however SC should not be used for critical clad welds as the SC process cannot provide weld fusion guarantees especially on parts > 4 mm and short circuit will too frequently produce poor weld tie-ins, extensive weld pore defects and spatter. MIG spray is simply too hot for cladding and especially not suited for all position welds.

Hot / Cold Wire TIG: In contrast to the available MIG weld modes, the automated Hot / Cold Wire TIG process used for clad welds provides far superior weld quality, however the automated traditional Hot / Cold Wire TIG clad weld process depending on the weld post ion or part thickness can be a "sensitive process with wire feed restrictions" and often the automated TIG welds will reveal small pores, inclusions, occasional lack of fusion subjecting the welds to weld rework and further machining.

If you would like to reduce clad weld repairs and improve material flow from the weld shop through the machine shop, please note that the TIP TIG process has the potential to attain a first time manual and automated pipe and valve clad weld quality never before attained with traditional Hot / Cold Wire TIG or Pulsed MIG.

TIP TIG and automated ID bore welds.


TIP TIG Inconel Bore clad weld made for oil industry application.
Note this was the first piece produced.
No test welds or playing around with weld data. No AVC or
sophisticated, costly automated equipment required.

It takes less than a 30 minute demonstrations to show that the TIP TIG process will
produce superior all position automated clad and weld quality than the regular
Hot Wire TIG, Pulsed MIG and Short Circuit process. Live video.



Click on the Evolution of TIG icon if you want a TIP TIG brochure.






Left: Traditional TIG. Two hands and a foot control, high skills, low amps,
inconsistent wire feed, numerous starts / stops and excess weld heat.

Right: In contrast TIP TIG, one hand, more relaxed. Higher weld
energy, consistent wire feed rates and welding much faster.

IF VIDEOS STALL REPLAY TWICE, BETTER SECOND TIME.

When you can control the TIP TIG weld wire delivered you can apply manual weld process controls to those pipe welds and you can apply weld process controls to any weld weld application.	Most TIP TIG pipe fill passes are welded with 200 to 400% greater weld deposition than that attained with regular TIG, that produces higher weld speeds with much lower weld heat input.
TIP TIG PIPE ROOT First time user.	TIP TIG PIPE FILL First time user.

 

EVERY TWO - THREE MONTHS WE HAVE A TIP TIG WORK SHOP AT OUR FACILITY LOCATED
AT THE PHILADELPHIA NAVAL YARD. NEXT WORK SHOP JULY 15-16 2010.
TO REGISTER OR TO HAVE A TEST PIECE WELDED,
CLICK ON THE WORK SHOP LINK AT THE TOP OF THE PAGE..


We invite you to visit our facility or send your weld samples.
Make an appointment: E-mail Ed@tiptigusa.com or tom@tiptigusa .com

COMPANIES WHO HAVE ATTENDED THE TIP TIG WORK SHOPS.

AREVEA - EXON - WESTINGHOUSE - WELDING SERVICES - KELLY CONSTRUCTION - TI-FAB
DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE CONTRACTING -
TRIUMPH FABRICATIONS - SIEMENS - ROLLS ROYCE - ENERFAB - DIAMOND POWER -
BODY COTE - SPACEX - NORTHROP GRUMMAN AND MANY MORE.

Examine the regular TIG automated weld on the left versus the manual TIP TIG P91 weld on the right.



The TIP TIG weld on right shows more energy than the TIG weld on the left
yet the TIP TIG weld reveals a much smaller HAZ.

The TIP TIG weld was done three times faster. Examine the TIP TIG weld continuity,
the weld cleanliness and quality of the manual TIP TIG weld.

IF VIDEOS STALL OR SLOW REPLAY TWICE, SHOULD BE BETTER SECOND TIME.



Examine a real world TIG versus TIP TIG weld cost evaluation.

TRADITIONAL TIG WELDING PROCESS.	THE TIP TIG WELDING PROCESS BETTER QUALITY 100 - 400% MORE WELD.
TIP TIG provides a dramatic solution for a weld industry that's facing increased labor and weld rework costs and a shortage of skilled welders. For a comparison of these two similar pipe welds, start the regular TIG welder on the left, when this video commences move the cursor to the 1 minute 20 seconds mark which is the actual start of this regular TIG pipe weld, then start the TIP TIG video on the right. When the right side weld is complete start this weld again and compare the TIP TIG process with the regular TIG process. The regular TIG welder on the left is walking that cup and working just as hard as the TIP TIG welder on the right. The regular TIG welder while aggressively working his torch nozzle is like most highly experienced TIG pipe welders working hard and depositing little weld. 2G - 5 G PIPE FILL PASS WELDS AND REGULAR TIG WELD COSTS: As you can see the highly skilled TIG welder on the left is using high current as evident by his TIG plasma intensity. If you use the clock on this video and examine the weld times shown. You will note with his weld start stops the regular TIG welder actually deposited 2 x 13 inch lengths of weld wire. The 26 inches of wire used on the pipe weld took approx. 3.5 minutes to deposit averaging 8 inch/min of 3/32 wire. Depending on the TIG welders skills and current utilized on the pipe the typical traditional manual deposition over an eight hour work shift would be 6 to 13 inch/min therefore using the regular TIG process we will work with an average 3/32 wire deposition 10 inch/min. 5G PIPE & REGULAR TIG WIRE WELD DEPOSITION: As we are comparing TIG with TIP TIG we will use a common TIG 3/32 (2.4mm) wire diameter utilized for pipe welding, the 3/32 (2.4 mm) wire versus the common 0.035 (0.9 mm) wire on a reel used with TIP TIG. The 10 inch/min of 3/32 TIG wire is the equivalent of approx. 70 inch/min of the 0.035 wire. The 70 inch of 0.035 wire is approx. 1 lb/hr or in a 20 minute duty cycle 0.33 lb/hr. TIG AND WELD DUTY CYCLES: With regular TIG welding, each hour we have grinding time for the many arc start / stops. For our cost evaluation with regular TIG we will use an average hourly arc on time of 20 min/hr. As the TIP TIG process is a "semi-automatic process" which should not require the use of a grinder or numerous arc starts / stops, you can expect to double the arc on time however with TIP TIG we will use a conservative duty cycle of 30 min/hr arc on time. 5G PIPE & TIP TIG WELD DEPOSITION AND COSTS: In the video on the above right, the TIP TIG welder is using an 0.035 wire reel. A conservative manual TIP TIG continuous weld wire rate for the vertical up fill passes on pipe < 3/8 wall would be 120 inch/min or approx. 1.6 lb/hr. With a 30 minute arc on time the TIP TIG deposit would be approx 0.8 lb/hr, in contrast to regular TIG (0.33 lb/hr) with TIP TIG on thin wall and small diameter pipe you could expect approx. >140% more weld for most of your pipe fill passes. On 5G thicker wall pipe and large diameter pipe or on rotated pipe you can anticipate TIP TIG wire feed rate increases in the range of 200 - 400% more weld. OTHER TIP TIG WELD QUALITY AND COST BENEFITS: Another cost benefit with TIP TIG is the improved weld surface tension and agitated weld pool may enable a reduction in the traditional pipe groove weld preps. The higher TIP TIG weld energy and unique weld pool also produces less weld defects such as lack of fusion and porosity. TIP TIG WELD WIRE & WELD GAS COST REDUCTIONS: You may be surprised to know that your regular TIG wire costs may be approx. 25% more than the MIG wires you will purchase with TIP TIG wire spools. When you can weld faster than traditional TIG process, with TIP TIG you can easily reduce your gas costs by 25 - 50%. As TIP provides more weld energy and agitates the weld, argon - helium and argon - hydrogen mixes are typically not required. TIP TIG AND WELD HEAT INFLUENCE ON MECHANICALS OR CORROSION: In contrast to the SMAW and the traditional TIG processes, the higher weld speeds not only reduce labor cost they also dramatically reduce the weld heat input providing less weld oxidation and smaller heat affected zones. This is particularly beneficial with heat sensitive applications. With the increased TIP TIG weld current combined with the hot wire weld current, the increased TIP TIG weld energy and agitated welds, duplex, stainless and nickel alloys are no longer sluggish and the greater TIP TIG parameter range is especially beneficial for duplex as it provides greater control of the austenite / ferrite formation. Heat sensitive P91-92 applications thrive on the the higher TIP TIG weld speeds and the small TIP TIG HAZ. Inconel, Stellites, Stainless, Monel, Aluminum, Copper, Brass or Carbon steels, it does not matter what the alloys are, the real world TIP TIG weld benefits will be extensive. TIP TIG AND LOWEST WELD FUMES: In contrast to all available manual welding processes, TIP TIG should produce the lowest possible weld fumes and most stainless applications should rarely require exhaust systems. For more TIP TIG info call Ed Craig at 828 658 3574 or call his cell 828 337 2695...

 

IF VIDEOS STALL OR SLOW REPLAY TWICE, BETTER SECOND TIME.

TIP TIG. FILL PASS BEFORE CAP. THIS TIP TIG WELD IS BETTER QUALITY THAN MOST COSTLY AUTOMATED TIG WELDS AND HIGHER DEPOSITION. TIP TIG TRAVEL SPEED CONSTANT, WIRE FEED CONSTANT. WELD CURRENT CONSTANT. MUCH GREATER ARC ON TIME, MUCH LESS ARE STARTS / STOPS AND COMFORTABLE FOR THE WELDER.

If you TIG, Pulsed MIG or flux cored high quality weld
applications, it's time you looked at TIP TIG.

A PICTURE IS WORTH A THOUSAND WORDS. THIS TIP TIG
HORIZONTAL FILLET WELD IS MADE WITH A MIG WIRE FEED RATE.

TIP TIG MANUAL 6 mm FILLET WELD. ALLOY 400. 3-4 LB/HR. EXAMINE THE TIG
WELD ENERGY, THE WELD CONSISTENCY, SMALL HAZ, WELD CLEANLINESS & WELD CONTINUITY.

TIP TIG Inconel Screw Weld:
Welding Wire: Inconel-625.
Weld wire size 0.045 (1.2mm).
Shield Gas Argon.

Typical TIP TIG amp range 300 - 380A. Weld deposition rate for an application like this would be approx 3 - 4 lbs/hr.

Remarks: For those of you that use costly helium argon mixes, these and other gas mixes are rarely required with TIP TIG as this process enables higher weld energy along with the unique weld pool agitation.

With TIP TIG highest first time weld quality should be consistently attained. Thanks to the TIP TIG high weld energy and puddle agitation, the welds were 100% free of pores. Note the one hand Inconel welds made with ease.

CLADDING OR HARD FACING SPECIAL ALLOYS LIKE STELITE 1 - 6 WITH TIP TIG
AND YOU WILL SEE WELD BENEFITS LIKE SUPERIOR WELD QUALITY, LOWER DISTORTION
AND DRAMATIC REDUCTIONS IN PRE-HEAT AND INTERPASS TEMPERATURES.

TIP TIG and P91 Pipe Welds: With traditional TIG root and SMAW for the P91 fill passes, it would take 4 hours to do each of the critical "P91 pipe joints shown on the left, if instead of SMAW you are using the slow traditional TIG process you are applying excess weld heat to the heat sensitive P91 pipe joints.

Photo on left. The TIP TIG process was qualified by SIEMENS in Germany for both the P91 root and for the pipe fill passes. For an application like this in contrast to regular TIG, the TIP TIG weld would deposit an average of 150 to 400% more weld.
Note Using TIP TIG, Siemens attained the best weld quality it had ever attained on any pipe welds.

Apart from the superior weld quality from the TIP TIG process, weld shops benefit with a process that gets the job done one hundred to four hundred percent faster, provides superior weld quality and always provides lower joules.

With TIP TIG it took approx. 55 minutes to fully complete each of these P91 weld joints and of course the TIP TIG welds were free of defects.

WELDING P91. ASME SA 182-F91. ASTM A199 Grade T91. TIP TIG IMPACT PROPERTIES.
Impact values attained from above manual TIP TIG fill pass welds. ISO-V(J) at 20° 100-120 J.

 

TIP TIG or SMAW. Every weld shop knows the weld issues generated with the SMAW process. First time quality is attainable with SMAW as long as the welders have the "highest skills, a grinder and electrodes they can consistently rely on" which these days is a rare combination. If all position capability, optimum weld cleanliness, weld fluidity, weld continuity, weld uniformity and low weld heat input are factors that will benefit your weld shop than give consideration to the TIP TIG process.

When you combine the controlled TIP TIG wire feed, with the increased weld current capability and unusual TIG arc dynamics, the TIP TIG pipe weld benefits on any application are improved weld fluidity providing better side wall weld fusion with lower weld heat input, this applies to any alloy and any application.






FOR QA AND WELD SHOP PERSONNEL, THE MANUAL OR AUTOMATED TIP TIG PROCESS SHOULD "SIMPLIFY WELD PROCEDURES THE WELD QUALIFICATION AND WELDER CONFORMANCE"..

For the typical weld shop, think about the variety of the weld equipment and weld consumable options. Welders will daily use TIG - SMAW - MIG - STT - RMD - Flux Cored and Metal Cored and too often many welders who lack process control expertise will "play around" with their weld controls. What about those complex pulsed MIG weld procedures which often will have to change when that new ever evolving Pulsed MIG power source is introduced to the weld shop and lets not forget the twenty to forty MIG gas mixes that your shop has tried in the last few years.


KIS - KIS - KIS: As someone who has spent 40 years simplifying and optimizing weld quality and productivity and has developed hundreds of weld procedures in 12 countries, I know the importance of keeping things simple in the weld shop. When weld shops have to start thinking about MIG Short Circuit - MIG Spray - MIG Globular - MIG Pulsed - MIG STT - RMD - CMT - Gas Shielded Flux Cored and the traditional TIG and SMAW processes and numerous weld consumables, you know weld issues are always around the corner and life in the weld shop is not going to be simple. In contrast, with TIP TIG you will have one weld gas argon and two or three simple wire feed and amp weld settings and that's all any weld shop will require to produce cost effective, defect free manual or automated welds on any weld position, any application and on any weldable materials.




WELD ERGONOMICS & WELD FUMES:

[] The TIP TIG water cool torch is much lighter than any MIG or flux cored gun.

[] TIP TIG weld fumes are the lowest possible from the argon inert gases and higher TIG weld speeds. The bottom line, exhaust equipment is typically not required for the majority of TIP TIG welds even when welding with stainless or other high chrome weld wires.



Note the lack of stainless TIP TIG weld fumes shown in the left photo in contrast to the weld shop on the right using flux cored and stick welding.

Please remember that the majority of MIG and flux cored steel welds requires active gases such as CO2 or oxygen. The reactive MIG and flux cored gases in combination with electrode positive influence both weld fume content and weld porosity. A weld bonus that should be appreciated by any weld shop is irrespective of the alloy or application, the TIP TIG process will always provide the cleanest welds with the lowest possible weld fumes.

 

TIP TIG. Smoke Free. Spatter Free. Defect Free Welds.
Simple to use at Pulsed MIG Deposition rates.

TIP TIG, the more complex the alloy to be welded, the better the weld results.

TIP TIG APPLICATION: MANUAL STAINLESS
TUBE TO SHEET WELDS.

With any alloys in which small weld tubes or pipe welds or welds on thin gage are required, the TIP TIG process with it's unique weld energy capability and control of the weld wire with high weld speed capability will produce far superior weld quality to traditional TIG - Plasma - Pulsed MIG - MIG - RMD - CMT - STT.

If manual welding a common application like the stainless cooling tubes on the left, in the past you would typically get the best manual weld quality from the "orbital weld equipment" and the conventional TIG process. If instead you used the manual pulsed MIG process, you would frequently produce welds in which the weld tie-ins and fusion would occasionally be suspect, the spatter and weld heat would be a concern and the manual MIG weld appearance would be irregular.

A traditional manual TIG welder would on this stainless tube application require high skills to feed low, inconsistent wire feed rates and again excess weld heat and distortion would create concerns. The inconsistency of the slow, manual wire TIG feed rates and the individual manual techniques added to the different wire to work placement from each TIG welder would typically be indicated in an irregular external weld appearance.

This company after trying TIP TIG never look back. Take a close look at the manual TIP TIG stainless tube welds produced on the right. These welds were made by the TIP TIG welder in the above left picture. The TIP TIG welds were made one to two times faster than conventional TIG. In contrast to TIG, the TIP TIG welds benefited from the higher weld energy, the controlled fixed dynamic wire feed, the exact wire to tungsten and wire to arc placement and less arc start / stops.

Also with the TIP TIG tube fillet welds, note the weld cleanliness and minimal weld heat affected zones generated by TIP TIG. The fast TIP TIG weld travel rate is a great benefit for those concerned with controlling weld distortion and weld appearance. Many experienced weld personnel would look at the TIP TIG manual welds in the right photo and logically assume they were done with an "automatic orbital TIG process". By the way I should know what automated tube welds look like as I was the North American Weld manager for ABB Robot Automation. Continue with tube welds in the next section.

TIP TIG SOLUTIONS TO STAINLESS EXHAUSTS. MINOR MIG SPATTER CONCERNS.
An automotive supplier used Fronius MIG - CMT for welding stainless steel exhaust systems. On the exhausts the low spatter CMT process produced "small amounts of weld spatter" and the company could not deliver the parts without grinding hundreds of parts each shift. The automotive company looked for a solution and switched to TIP TIG. The TIP TIG equipment slightly increased the weld productivity and the TIP TIG welds had zero defects on parts that required no cleaning.



TIP TIG. SMALL DIAMETER STAINLESS TUBES TO SHEET:
For the smaller diameter stainless tube welds on the right the easy to use TIP TIG process enabled the welder to use "two hands" on the light weight torch to provide ultimate manual control of the TIG torch on the normally difficult to weld, 3/4

Heat exchanger material: 1.4571
Tube Diam 3/4 inch (18mm).
2 layer weld required.
Remarks: Welds must be defect free.
TIP TIG Weld time: 15 sec/weld.

On these TIP TIG tube to sheet welds note the weld tail on each weld. The tail was a customer requirement to keep arc starts /stops out of the welds. This manual TIP TIG welder also benefited from two hands on the torch and the controlled, fixed wire feed rate which enabled these welds to be done 3 times faster than regular manual TIG. The controlled TIP TIG wire feed and consistent wire to tungsten / arc placement provided superior welds than the manual TIG pulsed MIG previously used. The TIP TIG welds produced the lowest distortion and were defect free. As with most manual TIP TIG welds, these welds look as good as "mechanized welds"

TIP TIG Tube to Sheet Test Welds.

TIP TIG ENABLES TWO HANDS ON THE TORCH AND THE TUBE TO SHEET WELD UNIFORMITY AND CONTINUITY AROUND 360 DEGREES ENABLES MANUAL WELDS THAT LOOK LIKE ORBITAL WELDS.

If video pauses let it play through and repeat, usually better the second time.

HOW TO ATTAIN SUPERIOR TITANIUM WELD QUALITY AT MUCH LOWER COSTS THAN YOUR TIG WELDS.

With attaining optimum Titanium welds, reducing the weld heat is a great benefit. Take your best TIG weld on any titanium application and we will show you on any manual or automated welds that TIP TIG will deliver superior weld quality with 100 to 400% faster weld travel rates.

Welding Titanium castings or fabrications. With the increased TIP TIG weld speeds think of the weld heat reduction you will achieve and the less concern you will have for distortion or weld oxidation. With the TIP TIG weld puddle agitation, think about the reduction in small pore weld defects. With the titanium wire tip never out of the protected argon arc think about the weld consumable waste you will prevent.

Note: Thanks to the higher TIP TIG weld speeds, we have made TIP TIG fillet welds on titanium parts >5 mm without using a gas trailing and attained complete silver color welds without any indication of oxide contamination on the welds or on the parts. I am not recommending not using a trailing shield. I am simply showing those interested in welding titanium that with TIP TIG the conventional trailing gas shield is often not necessary. Please remember TIG is not regular TIG, the TIP TIG weld process on any alloy should always provide a superior weld quality and production level never that are not attainable with regular TIG.

Titanium TIG and TIP TIG Welds.
If video pauses let it play through and repeat, usually better the second time.

TRADITIONAL ORBITAL TIG ON GRADE 2 TITANIUM	MANUAL TIP TIG ON GRADE 2 TITANIUM
While using the slow manual or automated TIG process, there is always concern about the oxidation effects on Titanium alloys. Typically manual or mechanized titanium TIG welds on parts over 3 mm will be carried at weld speeds in the 3 to 6 inch/min range. To protect those low speed high heat welds, trailing shields are a critical weld requirement to minimize the effects of oxidation. When welds are subject to oxidation you know weld porosity has to be an issue. The high TIP TIG weld speeds and weld TIP TIG weld agitation will produce the cleanest possible titanium welds.	With either the manual or automated TIP TIG process, TIP TIG titanium weld speeds will be much faster. The higher weld speeds typically 10 to 30 inch/min enable the TIP TIG welds on on some titanium applications > 5 mm to produce 100% silver welds without the use of a trailing shield. If your organization uses regular TIG on Titanium, you will be pleased to know that with TIP TIG, those manual or automated titanium welds will typically be carried at 100 to 400% faster with TIP TIG and these welds should always have be able to provide superior weld quality.

As reported in the 2009. September. AWS. Weld Journal, the above (left frame) orbital Titanium welds are being carried out on US Navy ships. On one ship approx nine orbital TIG weld units were used to weld CP Grade 2 titanium welds. These welds were required on more than 12000 feet of titanium pipe which was used per ship. Using traditional TIG, for the simple 360 degree titanium orbital lap welds, they welded at a weld travel speed of 3 - 4 inch/min. If they had used the TIP TIG process the welds would have made the same orbital welds with no quality issues at minimum weld speeds of 12 to 30 inch/min.

MANUAL TIP TIG WITH AUTOMATED WELD QUALITY.
SMALL CRITICAL WELDS FOR TESCOM.

TIP TIG Welds: TESCOM Material: 1.4404 Tube: Diameter 20 mm x 5.5mm wall thickness. Filler material: 1.4430. This manual weld required 3 passes for the almost 1/4 (5.5 mm) weld prep. In contrast to traditional TIG, the manual TIP TIG welds were more uniform and for those that care about weld costs, the TIP TIG weld time reduction was 100%. Note the small weld heat affected zone from the 3 TIP TIG weld passes.




TIP TIG Hastelloy C22
Welding Wire: Hastelloy C22
Welding Positions: 2G.
Remarks: Highest quality, lowest oxidation, defect free, great continuity full penetration weld.

Note the TIP TIG Hastelloy C22 weld continuity, the lack of oxidation and weld cleanliness and the small HAZ. The TIP TIG manual weld speed was 300 - 400% faster than traditional TIG. It's not possible to duplicate this TIP TIG weld quality with traditional manual TIG, flux cored or pulsed MIG.

TIP TIG provides extensive weld benefits
to the beverage and food industries.

 

TIP TIG TWO SIDE ROOT WELDS ENABLE THE WELD SHOP ON MANY APPLICATIONS TO ELIMINATE TANK OR VESSEL PURGING ON ALLOYS THAT REQUIRE ROOT BACK SIDE GAS PROTECTION.

NOTE: SEE THE PHOTO ON THE RIGHT AND VIDEO BELOW.

When you are dealing with code quality welds,
weld rework, NDT costs, weld grinding, gouging weld cleaning and weld skills inconsistency, all have an impact on your companies profits, the TIP TIG process addresses those issues.

 

 

Manual 2 Side TIP TIG. Horizontal Duplex Welds.
Applicable to all alloys that require back side root protection.

If video pauses let it play through and repeat, usually better the second time.



This plate is the weld qualification for a duplex brewery tank. The two
sided TIP TIG welds eliminate vessel and tank purging and provide
exceptional control of the root and ID root profile which is important in
the food and beverage industry. This company purchased 27 TIP TIG units,

Note how comfortable the welders are as they hold the light weight TIP TIG torches. Also note how instead of worrying about manual feeding a 3/32 TIG wire at an average low wire feed rate of 8 to 12 inch/min on these duplex horizontal veer groove welds they are constantly feeding 200 to 400% more weld wire and using their other hand for improved stability of the TIP TIG torch.


As with all TIP TIG welds, examine the minimum HAZ on these duplex welds, note the remarkable weld cleanliness and the weld fluidity with the duplex welds. You know this weld will pass any weld mechanical requirements and not fail any NDT tests.

WHY STRUGGLE WITH FLUX CORED OR PULSED MIG WHEN YOU
CAN PRODUCE MANUAL TIP TIG DUPLEX OR STAINLESS
OVERHEAD UNTOUCHED WELDS THAT LOOK LIKE THIS?

TIP TIG duplex over head weld on 5/8 duplex:


Difficult sluggish alloys and difficult weld positions are no longer a
concern with TIP TIG. This lean duplex, TIP TIG weld is made with DX2101 MIG wire.
Note the large weld control, lack of oxidation, weld cleanliness and weld continuity.







Do your untouched vertical up duplex welds look like this manual TIP TIG
weld and would your welds be free of weld defects?

This vertical up TIP TIG duplex weld was made by a a first
time user of the TIP TIG process.




ZIEMANN HAS TO PRODUCE 18 DUPLEX TANKS FROM 12 TO 17m DIAMETER AND THIS
COMPANY TURNED DOWN REGULAR TIG, PULSED MIG AND FLUX CORED AND SELECTED TIP TIG.





These duplex tanks will be built into ships to transport orange juice or other beverages. For these
types of containers exceptional weld quality is required. Note on this massive fabrication
application the outstanding all position full penetration weld quality, no weld cleaning,
no weld spatter, no distortion issues and no weld rework.



The duplex plate was protected with a zinc rust inhibitor and the
welder wears a ventilated hood, yet note there are no
evident weld fumes from the TIP TIG process.

If video pauses let it play through and repeat, usually better the second time.

With TIP TIG. The TIP TIG welder requires no foot control, the welder can use one hand to steady himself on the pipe, or use two hands to provide further stability to the weld torch. Don't forget these pipe welds also reap other benefits from the controlled wire feed input, the constant wire feed to optimum arc position, no weld starts / stops, higher wire feed rates and lower weld heat input, higher weld current and an agitated weld puddle, all of which can combine to produce superior weld control.

REGULAR TIG VERSUS TIP TIG WELD DEPOSITION DIFFERENCES.

This table represents the most common all position steels and alloy steel applications.

[1] Pipe Root	Regular Manual TIG wire feed rate. 10 inch/min (70 inch/min)	Manual TIP TIG wire feed rate increase. 25 - 50%
[2] Pipe Fill Wall < 3/8 (a)	10 inch/min (70 inch/min)	100 - 200%
[3] Pipe Fill Wall > 3/8	10 inch/min (70 inch/min)	100 - 300%
[4] 1/8 Fillet	10 inch/min (70 inch/min)	100 - 200%
[5] 3/16 Fillet Great setting also for all position cladding	10 inch/min (70 inch/min)	> 150%
[6] 1/4 Fillet	10 inch/min (70 inch/min)	200 to 400%

Note: Red is conversion from 3/32 2.4 mm wire to 0.035 0.9 mm wire.
5G pipe weld figures are real world. You will have some TIG welders that will
deposit slightly more weld wire and there will be TIP TIG welders that
can provide higher wire feed rates. TIP TIG rates will increase with automation.

The TIP TIG welders using the 2 Side TIP TIG Root Technique on the vessel below.
Note low fume content from the welder providing root protection inside the vessel.

Material: Stainless Steel. Material thickness: 3/8.
Weld wire 0.035. (1 mm) ER 316LSi.
On this application the average weld speed is 10 - 12 inch/min.

On a stainless or duplex vessel like this there is no other manual
process that will deliver the quality that TIP TIG delivered.



Note the portability of the TIP TIG wire feeders ON WHEELS.

 

TIP TIG and WELDING ALUMINUM: When welding aluminum everyone is aware of the weld porosity concerns and negative effects of weld heat on the weld control and on the aluminum strength.

The two common weld process choices for aluminum are traditional AC / Variable Polarity TIG and and pulsed MIG. The traditional TIG slow weld speed creates weld heat build up issues. Heat increases the weld fluidity increasing burn through potential and adding to distortion. With pulsed MIG, weld porosity and lack of fusion is common and the REP pulsed MIG plasma creates a wide HAZ influencing aluminum strength.

ALUMINUM. TIP TIG versus PULSED MIG:
[] TIP TIG does not require an expensive push pull gun.
[] TIP TIG can provide narrow or wide focused weld energy from the TIP TIG power source variable polarity controls.
[] TIP TIG has greater pulsed weld controls.
[] TIP TIG has superior control of the arc starts and stops and better control of weld tie-ins.
[] TIP TIG can control the width of the oxide cleaning action.
[] TIP TIG can provide welds with superior weld fusion.
[] TIP TIG will can provide welds with less porosity.
[] TIP TIG can reduce weld crack potential.
[] TIP TIG can reduce weld preheat requirements.
[] TIP TIG will reduce weld distortion.




ALUMINUM: TIP TIG VERSUS TIG:

I made this manual - TIP TIG - 8 mm fillet weld with a 1/16 - 5356 reel of wire during Feb 2010.

[] As you can see with the photo on the right,
the TIP TIG 0.062 wire is fed at 125 inch/min delivering approx 2.8 lb/hr. (2.5 - 4 lb/hr is considered good MIG wire feed rates). In contrast a regular TIG manual welder would at the high end deliver less than 0.7 lb/hr.

TIP TIG can provide > 300% more weld than regular TIG. Try and get your TIG welders to feed 10 feet of 1/16 aluminum wire every minute. Also as TIP TIG welders are changing the wire every few minutes, the TIP TIG arc on time is considerably greater.

[] With traditional aluminum TIG manual welds, the slow weld speeds produce very high weld heat input,
that extra weld heat;

[a] increases the aluminum weld fluidity that can lead to less control of the weld,
[b] increases weld burn through potential,
[c] adds to weld distortion,
[d] weakens all aluminum alloys.

[] Faster TIP TIG weld travel rates dramatically reduce the weld heat input. With TIP TIG you will see greater weld uniformity in the welds produced. You will dramatically reduce weld distortion and enable less impact on welds's heat affected zones producing stronger parts.

[] TIP TIG enables agitated aluminum welds at higher weld current than traditional TIG. Those welds should produce aluminum welds with "less weld porosity and greater fusion".

[] The TIP TIG process for aluminum is readily automated. View TIP TIG aluminum WELD




A REMINDER OF TYICAL WELD ADVANTAGES FROM TIP TIG WELDS ON ALLOY STEELS.

[] TIP TIG provides it's own unique hot wire TIP power source and patent pending wire feeder and torch. The TIP TIG wire feeders are connected to a 4T water-cooled TIG welding power source that supplies HF.

[] TIG TIP welds with higher deposition rates than traditional TIG, so the TIP TIG weld gas costs will be dramatically reduced by 100 TO 400%.

[] TIP TIG uses standard 30 LB spools which in contrast to pre-cut TIG wire will dramatically reduce weld wire costs.

[] With one handed TIP TIG requirements and the lack of a foot control, TIP TIG reduces both physical and skill requirements for the welder.

[] TIP welds typically 100 to 500% faster than all traditional manual TIG welds.

[] The faster weld speeds from TIP TIG can in contrast to any process provides lower weld heat input into base metal. TIP TIG therefore produces the smallest possible HAZ, the lowest weld distortion, welds with the lowest weld stresses.

[] In contrast to traditional "automated" cold / hot wire TIG welds, TIP TIG provides superior weld quality and the process is much less sensitive to variables that can impact automated TIG welds.

[] In contrast to any weld process, TIP TIG welds will always provide superior weld fusion with less weld porosity.

[] TIP TIG provides the opportunity to reduce vee and "J" groove angles dramatically reducing labor and consumable costs.

[] In contrast to pulsed MIG, flux cored or regular TIG, the TIP TIG process provides superior weld quality for any all position weld.

[] Of all the available manual or automated weld processes TIP TIG produces the lowest weld fumes and as TIP TIG welds require no grinding there is no concern for airborne grinding particulates.

[] In contrast to pulsed MIG. SMAW and flux cored, TIP TIG dramatically reduces arc start / stop weld defects, which are common with pulsed MIG, flux cored and traditional TIG.

[] TIP TIG brazing can be as fast as MIG brazing, but without the spatter and superior braze control.

[] With any clad welds TIP TIG will always provide superior weld quality and does not require costly Arc Voltage Controls typically associated with automated TIG applications.

[] TIP TIG needs minimal parameter changes for complex welds which simplifies the production of PQR's and weld procedures.

 

Over 20 years ago when I had to lead a project repairing failed welds on Textron Sting Ray tanks in
Thailand, (Ed in middle). I wish I had TIP TIG to do the weld repairs on the 278K Tensile Armor plate.

The defense industry welds many complex alloys and they will appreciate
TIP TIG as this process enables the highest possible weld quality with
increased weld production and less heat than regular manual TIG.

EVERY TWO - THREE MONTHS WE HAVE A TIP TIG WORK SHOP.
LOCATION PHILADELPHIA NAVAL YARD. NEXT WORK SHOP JULY 15-16 2010.
TO REGISTER OR TO HAVE A TEST PIECE WELDED,
CLICK ON THE WORK SHOP LINK AT THE TOP OF THE PAGE.


We also invite you to visit our facility and bring or send your weld samples.
Make an appointment: E-mail Ed@tiptigusa.com or tom@tiptigusa .com

COMPANIES WHO HAVE ATTENDED THE TIP TIG WORK SHOPS.

AREVEA - EXON - WESTINGHOUSE - WELDING SERVICES - KELLY CONSTRUCTION - TI-FAB
DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE CONTRACTING -
TRIUMPH FABRICATIONS - SIEMENS - ROLLS ROYCE - ENERFAB - DIAMOND POWER -
BODY COTE - SPACEX - NORTHROP GRUMMAN AND MANY MORE.

Take 15 minutes and attach the TIP TIG torch to a low cost carriage
and you have the worlds best quality welds.

If video pauses let it play through and repeat, usually better the second time.

TIP TIG 409 16 GAGE SEAM WELDS.	TIP TIG 409 16 GAGE SEAM WELDS
If you compared pulsed MIG with this 409 TIP TIG seam weld you would instantly note the superior weld quality from TIP TIG. While the full penetration Pulsed MIG may have weld fume concerns, weld oxide formation, weld spatter, distortion, undercut and require manual cleaning or weld rework, in contrast the TIP TIG welds would not create these common weld production issues.	Customer wanted to see the quality and ease of use in a production capability for TIP TIG on this seam application. Set up was easy and required about 15 minutes. Simply attach the TIP TIG torch to a low cost auto carriage. The part welded is the first of 3 test pieces provided. At TIP TIG we don't need to "play around to attain optimum weld results. Within a few minutes we were continuously providing parts as shown on the left. With automated TIP TIG seam gage welds like this, you can anticipate the welds would be made between 25 and 35 inch/min. (typical 300 to 500% quicker than manual TIG and compatible with many MIG welds.

TIP TIG. TWO SIDED ROOT WELDS. COULD BE PLATE, TANKS, VESSELS OR PIPE.
Any weld alloy that requires an open root and typically requires a purge to protect the root is an application in which you may want to consider TIP TIG. The above TIP TIG demo is simply a piece of stainless plate with an open root. Imagine this root is part of a 30 foot diameter duplex or stainless tank, how would you approach that root protection?

MANY WELDS DON'T HAVE THE WELD QUALITY REQUIREMENTS TO JUSTIFY TIP TIG.
IF YOU ARE INTERESTED IN OPTIMIZING YOUR MIG OR FLUX CORED MANUAL OR
ROBOT WELDS, CONSIDER ED'S WELD PROCESS CONTROL TRAINING RESOURCES.

ED HAS OPTIMIZED "ROBOT / manual WELDS" FOR HUNDREDS OF COMPANIES IN 12 COUNTRIES.
A FEW OF HIS PROJECTS, THE FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS -
CORVETTE FRAMES - HARLEY BIKE FRAMES - NEW VW BEETLE SEATS & THE
ABB ROBOT WELD DATA NECESSARY FOR CATERPILLAR'S WORLD'S LARGEST TRUCK.

If you are interested in Ed's manual and robot MIG and flux cored
weld process control training programs, click here.

 

For TIP TIG Videos go to the top of the page.

For MIG and Flux Cored weld process control
expertise visit Ed's other weld site, www.weldreality.com

TIP TIG Sales and Information North and S. America and Australia
visit www.tiptigusa.com. or call Ed Craig at 828 337 2695

 

For TIP TIG information in Europe and Middle East


Contact Darren he will be glad to help you, show you the best welds you
have ever seen or send you to the right person for your location.

My Scottish Buddy Darren Mathieson who unfortunately
has a thing for Haggis is available at;

TIP TIG UK. Ayr Road,
Galston. Ayrshire,
Scotland. United Kingdom. KA4 8LE
Phone +44 (0)1563 820505.
darren@mathiesonweld.co.uk



TIP TIG ARRIVES IN WESTERN CANADA

For Western Canada Sales or work shops contact

Jeremy Wright. Arc Innovations.
Phone: 780-437-4502
Mobile: 780-886-6642
Fax: 780-432-2420
jeremy@arcinnovations.net

For Eastern Canada sales contact ed@tiptigusa.com





TIG TIG ARRIVES IN AUSTRALIA
.
TIP TIG is pleased to announce our first distributor in Australia
A work shop will be presented in May at the new Perth location.
For Australian TIP TIG sales or work shops info contact;

Anthony Squire. 0459 150 338
www.proweldtraining.com.
anthony@proweldtraining.com

Before you leave TIP TIG, don't forget to visit the video sections and also visit
www.weldreality
the world's largest web site on MIG - TIG - Flux Cored
weld process controls

Ed's patent for improving boiler water wall stainless / inconel clad welds came into effect as of April / 2010. The patent was issued to Welding Services. Atlanta.

Ed's MIG clad patent improves the traditional, global, water wall, clad weld quality attained. The method used dramatically reduces boiler distortion and stresses and the amount of stainless or inconel clad material required by >25%. It's anticipated that Ed's unique MIG process control approach will become the standard for Welding Services who has been responsible for more than 75% of the water wall clad welds made in North America. Ed's MIG clad info available here.

More TIP TIG Weld Automation Data here.