TIP TIG welding is 100 to 500% faster than TIG with superior quality than traditional TIG - Pulsed MIG - FCAW

TIP TIG Welding

 


TIP TIG AND WELD AUTOMATION.

TIP TIG USA: 1901 Kitty Hawk Ave. Building 68. Naval Yard. Philadelphia. PA 19112.

For a TIP TIG quote call Nick at
215 389 7700.
For TIP TIG information reference your application call Ed at 828 337 2695.




TIP TIG USA is responsible for TIP TIG sales in
North & South America and Australia.

 


View the New automated TIP TIG Oscillator video below for your
automated weld / cladding applications.

TIP TIG AUTO WELDS AND CLAD APPLICATIONS:



From the pipe root to the pipe cap, TIP TIG always delivers the the highest manual and automated weld quality

Note the rapid weave oscillation speed for this 30 mm wide TIP TIG weld. What is remarkable about TIP TIG is you can do this with simple, low cost weld automation or sit a manual welder by the pipe and produce extraordinary pipe manual weld quality at manual weld speeds 200 - 300% faster than your regular TIG welders could achieve

View the untouched weld in the video below..


 

TIP TIG. NO DEFECTS - NO GRIND - NO OXIDES - NO SMOKE

When you want the best control of weld fusion or clad weld dilution, or the cleanest welds with the least possible internal weld defects, you select the TIP TIG process and achieve
those welds with the lowest possible weld heat input.

TAKE NOTE OF THE THE UNUSUAL, UNTOUCHED STEEL WELD CLEANLINESS AND VERY SMALL WELD HAZ .



GIVE ED CRAIG A CALL (828 337 2695) TO DISCUSS YOUR
AUTOMATED PIPE WELD OR CLADD TIP TIG APPLICATIONS.





HAVE YOU BEEN CONSIDERING THE AUTOMATED HOT OR COLD WIRE TIG PROCESS?

For those contemplating the purchase of traditional Hot / Cold Wire weld equipment, please be aware that in contrast to the TIP TIG process, the automated Hot Wire TIG processes does not change the TIG weld dynamics and cannot provide the manual or automated TIG weld quality or productivity attainable from the TIP TIG process.

Note the Hot - Cold Wire TIG processes are not suited for manual welding. With TIP TIG you have the world's best "manual and automated weld process.




CONSIDERING TIG WELD OR CLAD AUTOMATION.

Their are many differences between Hot Wire TIG and TIP TIG.


THE HOT WIRE TIG PROCESS HAS BEEN THE AUTOMATED WELD PROCESS OF CHOICE FOR TURBINE WELDS, AIR CRAFT PARTS AND WELDS IN NUCLEAR PLANTS. THIS PORTION OF THE SITE REVEALS THE DIFFERENCES BETWEEN HOT WIRE TIG AND THE TIP TIG PROCESS AND WE ALSO SHOW HOW THE MANUAL OR AUTOMATED TIP TIG PROCESS CAN PRODUCE SUPERIOR CLAD AND WELD QUALITY AND PRODUCTIVITY ON MANY ALLOY WELD APPLICATIONS:



AUTOMATED HOT WIRE TIG INFO: To provide additional energy into the rapid solidifying TIG weld, the Hot Wire TIG process simply provides a separate AC or DC power source that typically delivers 50 to 100 amps (pre-heats the wire) to a continuous fed weld wire that runs through the torch into a conventional TIG arc.

HOT WIRE TIG IS CONSIDERED A SENSITIVE PROCESS WHEN USED ON COMMON LOW TO MODERATE CURRENT TIG WELD OR CLAD APPLICATIONS:

On low to moderate current Hot Wire TIG applications, the Hot Wire current may only provide a partial weld energy solution to the rapid solidifying, small TIG weld pool.

Apart from the weld current and Hot Wire amps utilized, the weld energy is further influenced by the weld positions, the weld techniques, the arc length variations, the weld wire to tungsten position and distance, the part thickness, the alloys welded and the weld wire size and composition.


The problem with either the automated Hot and Cold Wire TIG process is no matter what type of sophisticated TIG power source is utilized, when using low to moderate TIG weld current, these processes will produce welds with a small fluid weld zone, and the rapid solidifying welds will have low surface tension and have poor receptivity to high wire feed rates.

A rapid solidifying Hot Wire TIG weld will influence the amount of weld wire that can be fed into the weld pool and also influence arc deflection. In the Hot Wire TIG weld current range < 250 amps, which is common for many all position welds and welds on parts < 5 mm, the traditional Hot Wire process is considered a sensitive process and this is the prime reason the automated Hot Wire process is poorly suited as a "manual semi-automatic
TIG process
".

To reduce the sensitivity to weld wire delivery of over 1.5 lbs/hr, the TIG weld dynamics have to change.

The regular, automated Hot Wire TIG Weld process is especially sensitive to weld wire delivery when welding or cladding with alloys using the moderate current range of 100 - 250 amps which is typical for horizontal and vertical up welds. For these welds or clad applications, the traditional, automated 0.035 (0.9 mm) HOT wire feed rates will typically be in the 100 - 200 inch/min range. To help maintain a stable arc and uniform weld energy level with automated Hot Wire welds, automatic volt control (AVC) equipment is used to rigidly maintain the optimum tungsten to work distance (arc length).

Note: Automated "Cold Wire" TIG welds simply provide the same weld deposition that a regular manual TIG welder can make. This is a process that is extremely sensitive to arc length variations and not suited to most manual welds.

With conventional Hot Wire TIG welds, many companies will purchase costly automated equipment to weld seams, deep groove, narrow gap alloy applications or provide bore welds or cladding for valves pipes and other components. From a weld quality perspective the automated, multi-pass Hot wire TIG welds will typically be excellent with small amounts of weld porosity, weld oxide inclusions and the occasional lack of weld fusion.
With the sophisticated costly, automated equipment the all position weld speeds will typically be 4 - 8 inch/min.



Traditional Hot Wire Weld Variables:

To enable consistent, controlled melting of the traditional constant fed Hot Wire into the small TIG arc zone with it's fast freeze, low surface tension weld pool, many variables require consideration. The variables will influence the wire delivery and the welds and the weld quality and productivity. The variables allow minimal room for change or error.

Common weld variables that affect conventional Hot Wire TIG weld quality and production;

[] weld current amount used and changes d
uring the weld,
[] arc length changes, (voltage variations),
[] tungsten size, profiles and condition,
[] wire feed issues,
[] weld travel speed variations,
[] weld wire to tungsten and weld placement
,
[] weld gas flow and coverage
,

[] inappropriate weld procedure data,
[] loor automated weld positioning equipment and lack of effective
equipment maintenance
,
[] lack of process control training for all relevant weld / management, supervisors, engineering and weld personnel,
[]
lack of best weld practices and lack of appropriate manufacturing instructions on the shop floor,
[] lack of awareness of the sensitivity of the Hot / Cold Wire process for specific welds and weld positions
,
[] pre-qualified weld procedures made on weld coupons that have little in common to the actual weld joints weld positions, torch angles and part thickness welded.


To reduce Hot Wire sensitivity to weld wire delivery and the many variables listed, it helps
if one can change the weld dynamics and the TIP TIG process provides those changes.


With either manual or automated low to moderate current TIG welds or clad welds, the key weld benefits attained from the TIP TIG process will be;

[a] TIP TIG changes the weld dynamics which slows the weld solidification and expands the fluid weld area, this simple action reduces the sensitivity to the weld to receiving increased weld wire rates,

[b] TIP TIG reduces the sensitivity of the tungsten to work distance allowing it to function as a manual process,

[c] TIP TIG always produces superior weld quality which is derived from the increased weld speeds that lower the weld heat and from the agitated welds.




MANUAL TIP TIG WELDS CAN PROVIDE HIGHER WELD DEPOSITION RATES THAN MOST AUTOMATED HOT WIRE TIG WELDS.

Increased manual / automated TIP TIG wire feed rates allow increased weld current and faster weld speeds. Increased TIG weld energy when combined with the TIP TIG unique weld agitation improves weld fusion potential and reduces internal weld defects.

In contrast to any weld process, the generous weld speeds with the electrode negative polarity TIP TIG process enables the lowest possible weld heat input providing the best possible weld mechanicals or corrosion properties. It's also beneficial with TIP TIG that you will generate the cleanest possible welds from welds that will have the lowest possible weld oxidation potential
.

Automated weld equipment Cost Savings. Before you consider spending a hundred to three hundred thousand dollars on an automated Hot Wire equipment package that utilizes the conventional Hot Wire TIG or Pulsed MIG process, let us show you the weld quality and productivity of either manual or automated TIP TIG welds. We can attain uniform, consistent weld quality for possibly a small percentage of what you intend to invest.



TIP TIG WELD APPLICATION INFO. Contact Ed Craig at ed@tiptigusa.com.


NEW WELD QUALITY AND WELD PRODUCT LIABILTY CONCERNS:

THERE ARE WELD STANDARDS BEING INTRODUCED IN THE OIL INDUSTRY THAT DEMAND ZERO WELD DEFECTS. WITH ALL POSITION, MULTI-PASS WELDS, ONLY ONE MANUAL - AUTOMATED PROCESS "TIP TIG" HAS THE POTENTIAL TO READILY ATTAIN THAT WELD QUALITY GOAL:

Many weld companies strive to improve their weld quality and minimize weld rework and the liability consequences of failed welds. In the power - oil and defense industries their is decreasing tolerance for any internal weld defects.


One of my clients had a unique Sub Sea Automated Weld Clad Quality Requirement that required "zero weld defects" on their valve bores. The clad welds were made with both inconel and stainless wires. The welds were made with Hot Wire TIG. The surface of the clad welds were machined, often revealing small pore, inclusions and lack of fusion weld defects. The Automated Hot Wire weld defects typically occurred in the valve bores (photo on the right) when the torch rotated and the moderate current welds were made in the horizontal weld position.


In a weld shop it's one thing to have an NDT visual weld standard that allows specific external weld defects, it's an entirely different situation when you have vertical up and horizontal clad bore inconel / stainless welds that require a machined clad weld surface that must be completely free of any visible weld defects.

WHY THE HOT WIRE PROCESS IS OFTEN CONSIDERED A HIGHLY SENSITIVE PROCESS
ON SPECIFIC WELDS AND WHY IT'S NOT SUITED FOR MANUAL ALL POSITION TIG WELDS.


With high current > 250 amp Hot Wire automated welds made in the flat position, and the additional Hot Wire current typically 80 - 100 amps, it's easy to maintain a consistent arc length as the plasma in the arc and welds will typically have sufficient size, energy with sufficient weld fluidity to receive high TIG wire feed rates.
However when the weld or clad current is less as required for specific horizontal / vertical up TIG welds or when the welds are made on thinner parts, the receptivity of the Hot Wire TIG welds to high wire feed rates is dramatically reduced and the welds can become very sensitive to the many variables that can influence the arc and weld.

When the automated Hot Wire TIG process is tried as a "Manual Hot Wire TIG process" the human variables that influence the arc, the weld wire delivery and the weld energy are dramatically increased making the Hot Wire process unsuitable for Manual use. In contrast
TIP TIG over comes those sensitivity issues.


For those persons considering Hot Wire TIG, please note on the low to moderate weld current applications, the TIP TIG process also provides Hot Wire current and TIP TIG also provides a unique weld agitation that dramatically changes the weld dynamics. The TIP TIG weld agitation slows down the weld solidification reducing the effects of sluggish alloys, improves weld fusion and reduces internal weld pores.





CLADDING WITH INCONEL, STAINLESS OR STELLITE CAN BE A SIMPLE
WELD JOB WHEN YOU USE THE RIGHT WELD PROCESS.




You have to manually clad the end of a pipe ID with Inconel. You could use
Pulsed MIG as shown on the LEFT or use TIP TIG as shown on the RIGHT.






LOW COST OPTIMUM WELD AUTOMATION:

When you have the semi-automatic TIP TIG process and weld parts on a rotary positioner you produce welds with extraordinary weld controls and welds with extraordinary quality and productivity.


A RARE COMBINATION. THE HIGHEST WELD QUALITY WITH GOOD PRODUCTIVITY.

AT TIP TIG WE PROVIDE MANUAL SEMI-AUTOMATIC OR FULLY AUTOMATIC SOLUTIONS TO ANY WELD APPLICATION.


At our TIP TIG facility in Philadelphia, if you require, we can build or supply you with moderate cost weld automation that enables extraordinary weld quality, however it's also important to note that most of our manual TIP TIG welds will be superior quality than what most automated TIG and Pulsed MIG welds provide.






AUTOMATED CLADDING IS A COMMON WELD APPLICATION AND THE
WELD SHOP HAS A VARIETY OF PROCESSES TO CHOOSE FROM,
HOWEVER NONE WILL PROVIDE THE WELD QUALITY ATTAINED BY TIP TIG.

When automated weld cladding is required, the weld shop has many weld process options. However when "defect free" clad weld quality is required there are a few practical weld process options.

PULSED MIG CLADDING. Pulsed MIG is fine for manual welds in which NDT is not applied to the internal weld quality. Pulsed MIG is a great process for external, boiler water wall panel clad welds in which the NDT weld quality criteria is typically weld surface chemistry requirements or visual specifications, however when the inconel or stainless Pulsed MIG cladding is subject to machining, X-Rays or UT examination, this process will likely reveal on many applications that the welds have lack of weld fusion, weld porosity, small pore inclusions and inconsistent weld ties-ins. Pulsed MIG clad welds will also frequently cause distortion and have negative impact on the parts mechanical properties.



MIG SHORT CIRCUIT CLADDING. Short Circuit (SC) is frequently used for clad applications, however SC typically generates many weld issues and should not be used for many "critical clad weld applications" as this process cannot provide weld fusion guarantees especially on parts > 4 mm, also short circuit will frequently produce poor weld tie-ins, extensive weld pore defects and weld spatter.

Note: Conventional MIG spray transfer is simply too hot for cladding and the high energy spray weld pools are not suited for most vertical up and horizontal welds.

HOT / COLD WIRE TIG CLADDING: In contrast to the available MIG weld modes, the automated Hot Wire TIG process when used for clad welds provides far superior weld quality, however this process as noted at this site when used with low to moderate current and using AVC will still be highly sensitive to many weld variables. That weld sensitivity restricts the wire feed rates utilized which also limits the weld current and weld speeds. Often the automated Hot Wire TIG welds will reveal small pores, inclusions, and occasional lack of weld fusion subjecting the welds to weld rework and further machining.

If you would like to improve your clad weld quality, 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 weld quality never before attained with traditional Hot / Cold Wire TIG or the Pulsed MIG process.




TIP TIG 409 16 GAGE SEAM WELDS. TIP TIG 409 16 GAGE SEAM WELDS

LOW COST TIG AUTOMATION WITH HIGHEST POSSIBLE WELD QUALITY & PRODUCTIVITY.

If you compared pulsed MIG with this TIP TIG seam weld or any other steel or alloy seam welds, you would instantly note the superior weld quality from TIP TIG. While the pulsed MIG may have fume concerns, oxide formation, spatter, distortion, poor weld appearence and possibly require manual cleaning or weld rework. TIP TIG welds would not create these common weld production issues.

The customer wanted to see the quality and production capability for TIP TIG on this full penetration weld seam application. Set up was easy. Attach the TIP TIG torch to the auto carriage BUG-O. Sophisticated equipment like complex Arc Volt Controls not necessary. Within 5 minutes we were producing the full penetration welded parts shown on the left. With automated TIP TIG seam gage welds such as this, you can anticipate the TIP TIG welds would be made between at weld travel rates between 25 - 45inch/min. That's 500 to 600% quicker than manual TIG and similar to pulsed MIG production.





To witness the extraordinary TIG weld Quality and Productivity improvements from the TIP TIG process on carbon steels, duplex, stainless, Titanium, Hastelloys or any alloy applications, we invite you to contact us to set an appointment for a visit at our Phily facility. You may want to send samples for welding in advance. Call Nick at 215 389 7700.




Philadelphia Naval Center is the home of TIP TIG USA.


 


We are looking in the USA - Brazil SA and Canada
for technical companies that want to sell TIP TIG.
Contact. ed@tiptigusa .com or tom@tiptigusa.com.
 



A FEW OF THE COMPANIES WHO HAVE PURCHASED THE TIP TIG PROCESS
OR ATTENDED THE TIP TIG OPEN HOUSE AND WORK SHOPS .


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



 

 

WITH WELD AUTOMATION ON PARTS THAT REQUIRE WELD QUALITY BEYOND THAT ATTAINABLE WITH THE MIG PROCESS, IT PAYS TO USE A WELD PROCESS THAT CONSISTENTLY DELIVERS THE BEST WELD QUALITY.

For the last thirty years, most of the global welding robots have been sold to car and truck plants and these plants typically use the MIG process with their robots.

W
ith auto / truck robot MIG welded parts, many plants have minimal, visual weld quality standards and daily weld quality issues are the norm. These are plants that have never grasped the concepts of MIG Weld Procces Controls.

Note: If NDT was used to check the internal weld quality on most car / truck ro
bot welds, the inability to meet acceptable weld quality would likely result in many plants closing their doors.
This is not a reflection of a poor weld process, its an indication of weak manuafacturing management and lack of process expertise.


WHILE PULSED MIG IS WELL SUITED TO SPECIFIC AUTO / TRUCK GAGE CARBON STEEL WELDS, (MOST WELDS MADE IN THE EASY TO WELD FLAT POSITION, YET
WELD DEFECTS ARE STILL COMMON. THE LACK OF USE OF THE PULSED MIG PROCESS FOR MANUAL, CODE QUALITY, PIPE STEEL WELDS SHOULD BE AN INDICATION THAT WHEN "ALL POSITION" CODE QUALITY WELDS ON HEAT SENSITIVE ALLOYS ARE REQUIRED, PULSED MIG SHOULD NOT BE THE WELD PROCESS OF CHOICE.



THERE ARE NO WELD QUALITY GUARANTEES WITH THE HIGHLY CONTROLLED AUTOMATED PULSED MIG PROCESS.

The Achilles heel of the automated Pulsed MIG process will always be excess weld heat, inconsistent weld fusion, inconsitent weld transfer, poor weld tie-ins, weld pores and oxide slag inclusions, porosity and occasional weld spatter
.

If you cannot attain consistent weld quality results from the automated pulsed MIG process when the welds are made in the flat position with optimum high end pulsed parameters, you should be concerned when you use lower pulsed parameters for all position pipe welds and those welds will be subject X-rays.

The Achilles heel of the pulsed MIG process is the process lack of ability to provide consistent weld fusion with optimum weld quality especially on parts > 4 mm. If you need more extensive evidence on this subject, visit my pulsed MIG sections www.weldreality.com.

Note: In my 600 page book, "A Management Engineers Guide to MIG, weld Quality - Costs - Training" published in 1996, I wrote close to a 100 pages on the pulsed MIG process and described the primary weld issues such as arc instability, lack of weld fusion and porosity issues. 15 years later in 2011 the same pulsed MIG problems exist.

FOR CODE QUALITY WELDS, IT'S LOGICAL THAT THE BEST MANUAL PROCESS SHOULD ALSO BE THE BEST AUTOMATED WELD PROCESS:
It's logical that the weld process that provides the best. consistent manual weld quality on alloys should be the weld process that delivers the best automated weld quality, however while the regular manual TIG process has typically delivered the best all position weld quality for most alloy applications, it was a process often poorly suited for weld automation.

The TIG weld rules change with the TIP TIG process. When quality welds are required to meet code requirements, we can show you in ten minutes that TIP TIG will produce both the best manual and automated weld quality.




Want to see a manual TIG process that
is producing 200- 300% more weld production

Thanks to the unique TIP TIG wire feed and torch, these two welders can hand over the TIP TIG torch to each other while maintaining the vertical up weld with deposition rates on this pipe at 300% greater than that attained by any regular TIG welder.

For those interested in obtaining consistent optimum manual and automated weld quality & productivity remember TIP TIG weld quality will always be superior than regular TIG


One inch (25mm) wall pipe with the manual TIP TIG welder depositing "agitated welds with superior quality" than regular TIG. The semi-automated
TIP TIG process is producing a weld quality and productivity beyond the automated Hot Wire TIG process. With this amount of torch movement its easy to see why TIP TIG is also suited to automated weld - cladd applications.

 

 



Question on Automated Hot Wire Welds:
Ed. in January 2007, we installed two AMET Inc. XM machine automated Hot Wire GTAW systems on which I have programmed over 500 weld pass programs, both cold and hot wire, for non-nuclear applications.  The biggest issue we have with hot wire GTAW is "keeping the weld wire in the very small sweet spot". Would TIP TIG reduce this wire to arc sensitivity?

Regards Frank. Diamond Power.

Answer. Frank with the TIP TIG process you would have the opportunity to use a TIG processwith much less concern for locating the wire tip into the very small rapid solidifying weld sweet spot. The TIP TIG agitated weld puddle expands the fluid weld area improving the wire to weld receptivity and also improves the weld quality.


Note: An important benefit of the TIP TIG weld agitation is that there is minimal concern for welding sluggish alloys like Duplex, Chrome, Nickel or High Carbon Alloys. On these and all sluggish alloys TIP TIG has the potential to provide superior side wall fusion and less weld porosity.

 


LOW COST TIP TIG CLAD WELD AUTOMATION:

It's this simple, you may be using traditional Hot or Cold Wire TIG for your clad weld applications, however please be aware these processes cannot attain the vertical up or horizontal weld quality / productivity achieved by the TIP TIG process.

Many bore clad welds are made with the inferior MIG short circuit or the Pulsed MIG processes.

The pulsed MIG processes when use for alloy clad welds may;

[a] provide excess weld heat in the welds and parts causing mechanical, corrosion or distortion concerns.
[b] create lack of fusion especially with the use of sluggish alloys,
[c] generate weld porosity or oxide inclusions,
[d] create weld spatter,
[d] produce poor weld tie ins.

With the clad equipment shown below typical vertical up TIP TIG clad "weld speeds" on applications as indicated in the photo would be between 15 and 25 inch/min. TIP TIG automated clad welds frequently will not require costly Automatic Height Controls (AVC) for the tungsten to work setting or other sophisticated equipment. No matter how complex the weld application or the alloy welded, with TIP TIG the weld procedures will be both few and simple.




TIP TIG Automated Stainless - Inconel Cladding.
Highest Quality at Lowest Costs

 
TIP TIG: LOWEST WELD HEAT INPUT. NO SPATTER. NO LACK OF WELD FUSION. NO ARC VOLTAGE CONTROLS. CLEANEST WELDS WITH NO REQUIRED WELD REWORK AFTER 100% X-RAY.





TIP TIG WELD AUTOMATION PROVIDES MANY BENEFITS:

In contrast to regular Hot Wire TIG, Short Circuit MIG and Pulsed MIG, with TIP TIG automated clad welds, an organization will have a weld or clad operation that can attain numerous weld benefits.

[1] In contrast to regular Hot / Cold wire TIG, with the TIP TIG automated process, the weld puddle dynamics are dramatically changed. The TIP TIG increased wire feed rates enable increased TIG weld current which combine with the TIP TIG hot wire current and unique weld pool agitation. The resulting larger TIP TIG fluid weld area enables an increase in weld production. The faster weld speeds that result dramatically can reduce weld heat input. With TIP TIG you would expect superior, multi pass TIG weld quality with less weld pores, less inclusions and improved weld fusion.

[2] In contrast to conventional low to moderate current, Hot wire TIG clad ID or OD welds, TIP TIG should readily allow a
50 - 100% increase in weld deposition rates which apart from the obvious labor saving costs also dramatically reduces the weld heat input. The faster TIP TIG weld speeds may also provide superior mechanicals and less distortion. .

[3] You can use pulsed MIG and short circuit for clad welds, however you may be delivering to your customer a product that has lack of fusion, weld pores, poor weld tie-ins and the parts will often be subject to excess weld heat.

[4] When ever you deal with a company that provides welded components to the oil industry you typically will find in that company has numerous weld procedures. When you set your clad welds with the TIP TIG process you likely will not require more than three sets of weld parameters for all possible weld or clad applications.








With TIP TIG increase the automated TIG wire feed rates, provide superior
welds and mechanicals while dramatically reducing the part weld heat input.




Multi Port Flow Diverter. Material Super Duplex. Euro Weld ER2594 2" Sch 80.

The company welding these parts would typically use costly AMET equipment with Hot Wire TIG, they now use the TIP TIG process and have attained dramatic improvements in both weld productivity and quality.

You can use the world's most costly, sophisticated, automated and Hot Wire
weld equipment, however if you want to increase your auto weld productivity by one to four hundred percent and improve both the weld quality, mechanical and corrosion properties, give consideration to TIP TIG.




FOR COMPLETE TIP TIG DESCRIPTION,
visit the TIP TIG home - manual pages of TIP TIG.

TIP TIG and a low cost $800 rotary positioner producing the
highest automation weld quality and productivity.




IF MIG OR FLUX CORED MEETS YOUR DAILY WELD QUALITY REQUIREMENTS, IT MEANS
YOU ARE NOT CONCERNED WITH INTERNAL WELD QUALITY AND YOU DON'T NEED TIP TIG.



TIP TIG WELD QUALITY: The TIP TIG process will provide your organization with the manual and automated capability to attain weld and clad quality levels way beyond the conventional TIG - Hot - Cold Wire TIG - Pulsed MIG and the Flux Cored process.





APPLICATION: AUTOMATED TIG ON 2205 DUPLEX INDUSTRIAL HEATING BOILERS 0.035 - 0.045 (1 - 1.2 mm) THICK.

Full penetration, defect free welds were required on these very thin gage duplex boilers shown in the left photo. The traditional automated Hot / Cold Wire TIG process was used for these duplex welds. While the parts were very thin. the duplex welds were sluggish (examine the irregular weld surface in photo). The poor weld wetting and weld irregularities influenced small pore porosity, weld fusion consistency and the weld travel rates that could be utilized.  The customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 - 15 inch/min.
 



The automated duplex tank welds were switched from Hot Wire TIG to the TIP TIG process. The TIP TIG weld parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire. The TIP TIG data is as follows:


TIP TIG Weld Current :   190 Amps
TIP TIG Weld Voltage:    12.5 Volts
TIP TIG Travel Speed:  
 35 inch/min.

Darren the UK TIP TIG Engineer reported, "the time we had at the tank facility was limited to a few hours. I think with a more time we could develop the TIP TIG weld procedure to readily exceed 45 inch/min providing a 200% increase in weld travel. The customer stated the TIP TIG duplex welds in right photo were defect free, the welds had a superior, less sluggish weld bead appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP TIG process was much more stable and consistent.

 

 

a
APPLICATION: AUTOMATED TIP TIG WELD
VACUUM BOILER COMPONENTS.


Material: Carbon steel.
Material thickness: 0.050 to solid rod.
TIP TIG Weld speed:
18 inch/min


This full penetration vacuum application required defect free welds and the regular automated Hot and Cold wire TIG provided instability and inconsistency resulting in unacceptable weld quality. A change to TIP TIG dramatically increased the weld travel, eliminated all weld issues and established consistent weld quality and productivity.

 



Every weld engineer and technician knows the difficulty with attaining
perfect weld quality on small round code quality applications like this
.



APPLICATION: Automated rotary TIP TIG Bushing 6 mm fillet welds. Low alloy steel.
High pressure hydraulic components.


TIP TIG provided consistent 100 % defect free welds. The bushing weld cycle time was 15 seconds. With pulsed MIG you would have had lack of weld fusion concerns and always poor weld tie-ins. There is no other process that will repeat the weld quality attained on this automated weld project.




TIP TIG IS EASY TO AUTOMATE AND SHOULD PROVIDE A
WELD QUALITY NOT ATTAINABLE WITH ANY OTHER PROCESS

TIP TIG DOES NOT HAVE THE WELD ISSUES ASSOCIATED WITH HOT WIRE TIG WELDS .

TIP TIG AUTOMATED WELDS
ON HYDRAULIC PARTS.



Instant high weld energy is always beneficial on small round welds where there should always be concern for the weld fusion and the weld tie-ins. The focused, TIP TIG arc plasma and agitated weld will provide superior weld fusion than pulsed MIG.


The TIP TIG hot wire current and weld puddle agitation will reduce weld porosity potential. N
ote the TIP TIG weld speed for the 6mm fillet, a weld speed that should remind you of a MIG fillet weld.

 

TIP TIG typically did not require arc voltage control equipment. Simply add a Bug-O or rotary positioner to the TIP TIG process and you have fully controlled automated welds that provide the best possible weld quality.





Note the weld smoke is from the drilling lubricants on the parts.





CONSISDER TIP TIG WHEN YOU NEED QUALITY
BEYOND REGULAR TIG OR PULSED MIG

TIP TIG ALWAYS OPTIMUM WELD QUALITY AT MIG SPEEDS.





Low Cost Automation. 17- 4PH Base Material Weld Sample welded with TIP TIG

OIL INDUSTRY PART. 60 TIP TIG WELD PASSES WITH MINIMUM CLEANING NOTE THE LACK OF DEFECTS THE GOOD WELD FUSION AND SMALL WELD HAZ. TIP TIG WELDS A DEEP "J" GROOVE 17- 4PH JOINT WITH ER630, 035 WELD WIRE. THIS MANUAL / ROTARY TIP TIG WELD IS MADE 300% FASTER THAN MANUAL TIG. MINIMAL WELD CLEANING AND ZERO REWORK.








APPLICATION:TIP TIG AUTOMATED STAINLESS or DUPLEX THICK WALL TANKS


Tank Wall Thickness 15mm.
TIP TIG Weld speed:
16 inch/min

How many companies would consider the TIG process a practical process for welding a 15 or 25 mm stainless or duplex tank or pressure vessel?

What you attain here from the TIP TIG process, is from the root to the cap pass you will achieve first time, defect free, horizontal vee groove welds made at moderate average weld speeds of approx 16 inch/min. You could readily achieve this weld speed with pulsed MIG or flux cored, however the question would be how confident would you be that the MIG and flux cored radiographs or UT will not find weld defects.


On applications like this duplex tank, the TIP TIG process should deliver x-ray quality welds with zero weld rework. For those interested in cost reduction this tank was not purged with any gas and no back gouging or grinding was required for the open root. The TIP TIG 2 side root weld method was used. For details email Ed ed@tiptigusa.com.

 



APPLICATION. A ROBOT BRAZED WELD THAT REQUIRED SUPERIOR COSMETIC WELD SURFACE:

TIP TIG robot success from the UK Cyberweld company. Robot MIG brazing was used on the Jaguar X150. A robot system with vision guidance had been installed to perform this MIG weld on the Jaguar roof joint. As this was a visible weld, the quality of the finish was critical and the system supplier had not been able to achieve the braze quality required by Jaguar despite working on the problem for a number of months with pulse MIG and other processes. Within a few hours for the weld set up, TIP TIG provided a consistent weld quality never before seen by Ford.


GREAT WELD AUTOMATION EQUIPMENT WILL NOT ENHANCE
A WELD PROCESS POORLY SUITED TO AUTOMATION:


For decades many robot integrators lacked confidence with the Hot Wire TIG process. These companies have found on many robot welds, clad or brazing applications, that the Hot Wire process was extremely sensitive to many weld variables and tight controls were necessary but difficult to maintain. TIP TIG finally provides a process thats comfortable on a robot.


At the 2010 AWS weld show, many companies were proud to exhibit their automated pipe weld equipment with the Hot / Cold Wire TIG process welding in the 5G position with typical 0.035 wire feed rates set 60 to 140 inch/min and weld travel rates at the low, high heat input of 3 - to 6 inch/min.

The automated TIP TIG process is in contrast to the traditional automated Hot / Cold wire TIG process, is a much more robust process. With TIP TIG orbital or manual all position welds on any carbon steels or alloy pipe 5G welds, the fill pass wire feed rates will typically be 120 - 280 inch/min. Think about the weld quality / production benefits and the dramatic reduction in the weld heat generated.











Application: AUTOMATED TIG SEAM WELDS.

Typical material: Stainless. Thickness 1.5 - 4.8mm
Full fusion butt welds. No prep. Welds must be defect free.
Typical averge TIG weld speeds range
6 - 12 inch/min.


TIP TIG on Hastelloys - Duplex - Stainless - Inconels or any Alloy seam welds, simply add TIP TIG to that seam welder and dramaticlly increase weld production with superior weld quality.





WELD DEPOSITION DRIVES WELD SPEEDS.
REGULAR TIG VERSUS TIP TIG PIPE 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: Green 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.

 

 

TIP TIG is a process that provides a unique, patent pending
mechanical solution to change the TIG weld dynamics





Advantages
from automated TIP TIG welds.

[] TIG TIP welds with higher deposition rates than traditional manual TIG and also with higher deposition rates than many automated Hot Wire TIG applications reducing weld labor costs.

[] TIP TIG uses standard 30 - 40 lb MIG wire spools reducing TIG wire costs and with the increase in weld speed look for a dramatic reduction in argon gas costs.

[] TIP TIG welds are less sensitive to the issues that occur with conventional automated Hot / Cold wire TIG applications.

[] TIP TIG faster weld speeds and the agitated welds can provide superior weld quality with lower heat input that can result in reduced distortion, less oxidation, cleaner welds with less weld stresses.


[] TIP TIG welds provide superior side wall weld fusion reducing lack of fusion defects and often enabling a reduction in Vee
or J groove weld edge preparation, dramatically reducing labor and consumable costs.

[] TIP TIG should always produce the lowest weld fumes and as weld grinding should be rare, less contaminated particles in the air.

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

[] TIP TIG in contrast to all MIG spray and pulsed MIG welds, can provide far greater control of small welds < 5mm.




 




For information on the suitability of TIP TIG for your organization,
contact Ed Craig 828 337 2695. E-Mail ed@tiptigusa.com

 





ED'S MANUAL AND ROBOT WELD PROCESS CONTROL RESOURCES.

ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES. A FEW OF HIS PROJECTS, THE FORD F150 FRAMES - VOLVO CABS - CORVETTE FRAMES- HARLEY FRAMES - NEW BEETLE SEATS AND THE WELD'S ON CATERPILLAR WORLD'S LARGEST TRUCK.





 


From optimizing and providing welding patents for automated, boiler water wall, pulsed MIG inconel clad welds for Welding Services Atlanta, to setting the robot welds on many of the most popular products sold in North America, if you want the training and educational resources to enable Best Weld Practices / Process Controls and optimize your manual / robot MIG and flux cored weld quality and productivity click here for Ed's materials.

 




WHILE AUTOMATION IS ABOUT CONTROL AND PRODUCIVITY TAKE A LOOK AT THE COST SAVINGS GENERATED
FROM THE MANUAL TIP TIG PROCESS THAT SHOULD ALWAYS PROUCE OPTIMUM WELD QUALITY.

TRADITIONAL TIG PIPE WELDING. TIP TIG PIPE WELDING
BETTER QUALITY 50 - 450-% 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 then start the TIP TIG video on the right and compare the TIP TIG process with the regular TIG process. The regular TIG welder is like many highly experienced TIG pipe welders, working hard and depositing little. Which welder looks like he is the most comfortable and applying the most control of the weld? Which welder is depositing 200 percent more weld wire?

2G - 5 G PIPE: FILL PASS WELDS AND AVERAGE TIG DEPOSITION RATES.

Watch the clock on the videos and examine the weld times shown. You will note in approx 60 seconds the left regular TIG welder actually deposits around 6 to 8 inches of 3/32 wire. For cost purpose, using the regular TIG process we will work with
a generous, average wire length deposition of 8 inch/min of 3/32 (2.4mm) wire = 0.8 lb/hr.

5G PIPE: TIP TIG VERSUS REGULAR TIG WELD DEPOSITION RATE & DUTY CYCLES:

ARC ON TIME: For our cost evaluation with regular TIG we use an average hourly arc on time of 20 min/hr. In contrast TIP TIG is a "semi-automatic process" so there should be less use of arc start / stops as there is no need to stop welding to get a new weld wire length. For this fundamental pipe cost analysis, TIP TIG requires minimum arc starts / stops, therefore for TIP TIG we use an arc on time of 30 min/hr.

REGULAR TIG "FILL PASS" PIPE DEPOSITION 0.26 TO 0.3 lb/hr. As we are comparing regular TIG with TIP TIG, we use the common 3/32 TIG wire diameter utilized for pipe welding versus an 0.035 (0.9 mm) wire on a reel with TIP TIG. The 8 inch/min of 3/32 TIG wire is the equivalent of approx. 56 inch/min of the 0.035 wire. That 56 inch of 0.035 wire is approx. 0.8 pounds per/hr. With a 20 minute arc time, the regular TIG welder when providing 5G pipe fill pass TIG welds deposits on average 0.28 lb/hr.


5G PIPE . TIP TIG FILL PASS WELD DEPOSITION AND WELD COSTS:

In the video on the above right, the TIP TIG welder is using an 0.035 wire reel. In contrast to the regular TIG weld depositing 0.28 lb/hr, a conservative manual TIP TIG 0.035 weld wire rate for the vertical up fill passes on pipe < 3/8 wall would be 130 inch/min = 1.8
lb/hr with a 30 minute arc on time thats approx. 0.97 lb/hr. In contrast to regular TIG depositing 0.28 lb/hr. (TIP TIG 250% more).

Note on thicker wall or large diameter pipe TIP TIG would deposit 200 - 250 inch /min = 3 - 3.7 lb/hr. 30 minute arc on time 1.5 - 1.9 lb/hr. (TIP TIG 400 - 500% more)


TIP TIG CAN REDUCE WELD PREPS. DRAMATIC LABOR & CONSUMABLE COST SAVINGS:

Another cost benefit with the TIP TIG process is the improved weld surface tension and agitated weld pool improves the flow
of weld metal and typically enables a reduction in traditional pipe groove vee and J groove weld preps. For example if you are using combined vee preps of 60 degrees consider with TIP TIG using 40 - 50 degrees.

TIP TIG LESS DEFECTS, LESS WELD REWORK, LESS LABOR COSTS:

The higher TIP TIG weld energy and unique agitated weld pool combined with continuous control of the weld wire to the optimum arc position and less arc start / stops, has to produces less weld defects such as lack of fusion and porosity.


TIP TIG WELD WIRE & GAS COST REDUCTIONS:

You may be surprised to know that your regular TIG wire costs may be approx. 25% more than the 30 - 40 lb MIG wire reels you will purchase for the TIP TIG. When you can weld faster than regular TIG as you do with TIP TIG, you can readily reduce your weld gas costs. When the regular TIG weld requires an hour arc on time and the TIP TIG weld is done in 15 minutes, depending on your flow rates you will only require 25 to 40 % of the argon you would normally use for regular TIG.

Note: As TIP provides more weld energy and agitates the weld, argon - helium and argon - hydrogen mixes are typically not required and even with sluggish alloys straight argon is the gas of choice.

TIP TIG FIRST TIME OPTIMUM MECHANICAL AND CORROSION PROPERTIES:

In contrast to the SMAW and the traditional TIG processes, the higher TIP TIG 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. Also in contrast to the Reverse Polarity pulsed MIG process, there will be a dramatic weld heat reduction from the Electrode Negative (dissipates the heat in part) TIP TIG welds.

TIP TIG A SOLUTION FOR SLUGGISH ALLOYS:

With the increased TIP TIG weld current combined with the hot wire weld current and agitated welds, duplex, stainless and nickel alloys are no longer sluggish. The increased TIP TIG paramete
r 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 HAZ. Inconel, Super Duplex, Stellites, Hastelloys, Stainless, Monel, Copper, Brass or Carbon steels, it does not matter what the alloys are, the real world TIP TIG weld benefits will be extensive.




Have you visted the TIP TIG home - manual - pipe pages and and viewed the remarkable weld videos?



North America: For TIP TIG technical
info E-Mail Ed Craig. ed@tiptigusa.com.

North America. For TIP TIG sales
info E-Mail Tom O'Malley. tom@tiptigusa.com.

North America. For TIP TIG parts / automation.
info E-Mail Nick Corso. nick@tiptigusa.com.



For TIP TIG sales or information in Europe and Middle East

Contact Darren Mathieson he will be glad to help you or send you to the right person.



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



TIP TIG WESTERN CANADA
.

For Western Canada Sales and work shops info 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.

We are looking for TIP TIG dealers for
distributors for Eastern Canada Texas and Brazil.
EMail Tom at tom@tiptigusa.com

 





Australia. TIP TIG sales, workshops or weld demos contact;

Brad Thomas. SFI Australia
Direct 03 5332 5312 Tel 1800 734 000
Fax 03 5338 2033 Email brad@sfiaust.com.au.
Web site. www.sfiaust.com.au


Weld Questions Ed Craig E-Mail ed@tiptigusa.com


To find out more on controlling manual and robot MIG or Flux Cored
visit weldreality.com the worlds largest web site
on MIG and Flux Cored Weld Process Controls

We are looking for TIP TIG dealers
for Canada. EMail Tom at tom@tiptigusa.com

 

TIP TIG Brochure Download

Click on the Evolution for the TIP TIG brochure


For the world's best MIG and Flux Cored Best Weld
Practices and Weld Process Control Education and Training Resources
visit Ed Craig's www.weldreality.com




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Site Established 2001. Ed Craig Weld Reality. E-Mail ecraig@weldreality.com. Phone Eastern Time USA 828 658 3574.