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

TIP TIG Welding

 

A FEW TIP TIG WELD PROCESS FACTS:



TIP TIG Welding Pictures


For at least six decades, traditional TIG has been considered the process of choice for attaining optimum manual weld quality on any metal application, however in this time period, the three primary manual traditional TIG weld process limitations have been;

[1] the TIG weld energy limitations influenced by the weld pool dynamics and the typical slow manual wire feed rates.
[2] the high manual TIG weld skill and dexterity requirements necessary for feeding the TIG weld wire.
[3] the inconsistency of the manual TIG techniques used and the accuracy and consistency of the weld wire to arc and weld puddle placement.

The patented TIP TIG and TIP Plasma process was invented in Austria by Ing.
Siegfried Plasch. Approx. a  thousand companies in Europe now use the TIP TIG process. As of July. 1. 2009. We are also pleased to announce the new patent pending Advanced TIP-TIG process.

A PRIMARY SKILL REQUIREMENT WITH  TRADITIONAL TIG WELDING IS THE WELDER’S ABILITY WITH ALL WELD POSITION WELDS, TO MANUALLY FEED A STRIP OF WELD WIRE AT THE RIGHT MOMENT INTO AN EXACT ARC AND WELD POOL LOCATION IN A MOVING FAST FREEZE WELD POOL. WITH THE TIP TIG PROCESS THESE MANUAL WELD SKILLS ARE NO LONGER REQUIRED.

 

 

 

 

TIP TIG is a unique manual and automated TIG wire feed control combined with a hot wire power source. TIP TIG  can operate with any TIG or plasma welding power source. The TIP TIG process deals with the traditional TIG limitations and enables both manual and automated TIG weld quality and productivity levels never before attained in the welding industry.

TIP TIG rarely requires a cold wire weld. When welding with TIP TIG or TIP Plasma welds. The patented TIP TIG wire feeder feeds a weld wire from a typical 30 – 50 lb MIG wire reel. In contrast to the traditional manual or automated hot and cold wire TIG, the TIP TIG wire is fed at a constant linear forward motion while applying a unique “mechanical action” to the weld wire. The TIP TIG wire entering the weld pool is superimposed with a high frequency, dynamic, linear “forward - backward motion”. This motion agitates the weld pool and generates a unique kinematic energy into the TIG weld puddle that provides unique TIG weld benefits. The following 10 TIP TIG weld benefits are typical many more could be provided.
                                         
1.  The TIP TIG weld wire motion removes the surface tension present in all weld pools, this changes the weld dynamics and results in a highly mobile molten weld pool which is receptive to higher than normal TIG wire filler rates associated with the conventional TIG  process and hot and cold TIG processes.

2.  The TIP TIG increased wire feed rates enable higher weld current per-application providing less opportunity for internal weld defects and weld fusion.

3.  The TIP TIG weld pool agitation and increased weld energy from higher weld current result in a unique weld pool that remains molten longer. The weld energy and agitation combination enable a greater release of weld gas oxide reactions and contaminates. The result is welds that will provide the least amount of internal weld defects. The TIP TIG agitation of the weld puddle will also reduces weld stresses. No other manual weld process can provide welds with the internal weld quality attained by TIP TIG.

4.  TIP TIG wire feed rates enable typical weld deposition rates in the range of 2 – 10 lb/hr

5.  On most applications previously welded by traditional TIG or the SMAW process, the TIP TIG higher weld deposition process  enables higher weld speeds. The increased TIP TIG weld speeds will dramatically lower the weld heat producing less distortion and producing smaller weld heat affected zones and provide welded parts with superior mechanical properties. For example, the heat sensitive P91 pipe weld joints are typically made with TIG or SMAW root and SMAW fill passes. Normal TIG on the fill passes was considered too slow, providing too much weld heat for the P91 parts. In contrast in Europe many P91 applications are now welded with TIP TIG which is used for both the P91 pipe / valve root and fill passes. (Photo is a P91 TIP TIG ) With the TIP TIG process, on all metals you can anticipate in the welds and base metals, optimum mechanical and micro properties.

6.  TIP TIG enables a TIG welder to use one hand or two hands on the weld torch. In contrast to traditional TIG, SMAW and pulsed MIG, the TIP TIG process dramatically reduces the weld skills required for any all position welds and of course when a welder can put two hands on the torch, you would expect the welder to attain greater weld control.

7.  For the majority of alloy applications, TIP TIG does not require argon helium or argon hydrogen mixes. Also in contrast to traditional TIG, as the TIP TIG process welds faster you should typically decrease your normal TIG gas consumption in the 50 to 80% range.

8.  In contrast to SMAW and traditional TIG, with TIP TIG the constant fed automatic wire feed dramatically reduces the weld stops and starts on any application.

9.  As TIP TIG typically welds 2 to 8 times faster than traditional manual TIG, the obvious labor cost reduction will be  very beneficial especially on Code quality welds where you get the benefits of  reduced labor costs with reduced weld rework costs.

10. In 2010 we will see new OSHA guidelines for weld fumes for alloys with chrome. As TIP TIG welds faster than traditional TIG, the TIP TIG process will produce less weld fumes than any other manual weld process, and with many stainless or nickel applications, it’s  likely exhaust equipment will not be required.

TIP TIG: On the over head TIP TIG pipe weld, (left photo) it was beneficial for the welder to use one hand for the torch and use the other hand to steady himself  while in this difficult weld position.

On the Inconel deep groove screw weld shown on the right, the TIP TIG welder is  depositing a TIG weld with MIG weld deposition rates. On this high amp application the welder appreciates the lack of heat on his left glove and thanks to the high TIP TIG weld speed, the weld fumes were as low as possible on an application like this. On this Inconel part the TIP TIG high energy weld puddle and wire mechanical action resulted in defect free welds and of importance to this customer, welds without porosity.  

TIP TIG & Weld Controls: An important advantage of the constant current TIP TIG process compared to MIG, Flux Cored is the fact that the constant current, TIP TIG welds like traditional TIG welds allow low voltages and control of the arc and weld without adjustment of the wire feed. Also TIP TIG as with many TIG welds can provide ultimate Ramp up, ramp down control of  the weld arcs and stops which are common weld defect locations.

TIP TIG and Weld Energy. In contrast to traditional TIG, the TIP TIG process provides consistent high
wire feed capability which as mentioned enables higher weld current potential reducing weld defects. The increased weld energy and unique weld puddle agitation improves weld fluidity which is especially important with sluggish alloys like duplex, chrome and nickel alloys. Note the fluidity, continuity and cleanliness of the P91 horizontal weld coupon on the right.

TIP TIG & Skill Requirements: As the power and oil industries laments over their concern for the shortage of skilled welders, its important to note that in contrast to traditional TIG, SMAW, flux cored and pulsed MIG, the one or two handed TIP TIG process with it’s light weight water cooled torch, will be the most simple process to use for any all position applications.


A PRIMARY SKILL REQUIREMENT WITH  TRADITIONAL TIG WELDING IS THE WELDER’S ABILITY WITH ALL WELD POSITION WELDS, TO MANUALLY FEED A STRIP OF WELD WIRE AT THE RIGHT MOMENT INTO AN EXACT ARC AND WELD POOL LOCATION IN A MOVING FAST FREEZE WELD POOL. WITH THE TIP TIG PROCESS THESE MANUAL WELD SKILLS ARE NO LONGER REQUIRED.


TIP TIG Weld Application Range: In contrast to all available weld processes, when welding manual and automated welds, TIP TIG provides a much greater operating weld current and wire feed range with the opportunity to provide optimum consistent, all position welds on parts from a few thousands of an inch to any thickness. Thin or thick applications in any weld positions. If the steel or alloys are weldable, TIP TIG will always provide the best welding quality.

TIP TIG Weld Costs: The welding industry is well aware of the weld quality benefits attained from the traditional TIG process. The TIP TIG process increases those weld benefits. Most TIG weld defects are generated from the weld techniques utilized and the weld energy delivered. TIP TIG delivers the weld wire in a consistent manner and that wire is  always delivered to the optimum arc location.  The additional weld current and agitated weld pool from TIP TIG dramatically reduces weld defects and weld rework. TIP TIG also enables high manual TIG weld deposition rates that can be similar to MIG or flux cored welds or be 2 to 12 times greater than the standard TIG and the SMAW (stick) processes. In contrast to regular TIG costs, TIP TIG uses MIG wire reels which should reduce weld wire costs and the TIP TIG gas costs will also be dramatically reduced.

Note: If you manully weld Titan with TIG you may waste thousands annualy on wasted titanium wire ends. With TIP TIG there is no concern for wire oxidation so no wire waste.

In contrast to SMAW, flux cored and pulsed MIG, the increased weld energy from TIP TIG will frequently allow a reduction in pipe and plate vee / J groove weld joint preparation further reducing weld labor and consumable costs. Many companies who use SAW for plate and pressure vessels will frequently use a separate process for the root followed by a back gouge, these companies can now use TIP TIP for the root and fill passes made in any weld positions, no back gouge and no weld rework required.

Note: If you weld stainless, inconel or duplex you will be aware of the high cost of purging large containers, tanks. pipes or vessels with argon, we can show you with many applications how with TIP TIG you could eliminate this costly practice.

Important. Please note that TIP TIG is a hot wire TIG process has full acceptance from all code bodies.

TIP TIG Weld Procedures: That new power plant or that new refinery extension if welded by TIP TIG could be built with a manual and automated weld quality and productivity never before attained and these facilities would typically require no more than two or three common sets of TIP TIG wire feed / amp weld settings for all the weld procedures. These setting would apply for any weld application, simply change the base material / weld consumable and add any heat treany weld position and any steel or alloy. You should also be aware that when welder needs to take that weld qualification test, the fool proof, easy to use TIP-TIG process will ensure the highest weld test pass rates.


TIP TIG and Automated Welds:
TIP TIG enables a narrow arc and dramatic weld speed increase with gage mechanize welds. On these stainless rolled parts which are typically welded in the 1 – 2 mm thickness range, the full fusion seam welds had to be defect free. The TIP TIG Weld Speed Range for an application like this would be  25 - 35 inch/min with no weld rework or clean up required. In contrast to the normal hot wire TIG process used with weld automation, TIP TIG is much more robust and enables higher wire feed capability. with improvements in weld uptime. If your automated welds require optimum weld quality give consideration to this process.




TIP TIG APPLICATION: MANUAL WELDING STAINLESS COOLING TUBE WELDS.

With any alloys in which small weld tubes or pipes 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 speeds will produce optimum weld quality and productivity. 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 conventional TIG process and orbital weld equipment. If you used the manual pulsed MIG process, you would produce welds in which the weld tie-ins and fusion would occasionally be suspect and the manual MIG weld appearance would be irregular. A traditional manual TIG welder would on this application require high skills to feed low, inconsistent wire feed rates with weld current compatible to that low wire feed. 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 and in the internal weld quality.


Take a close look at the "manual" TIP TIG stainless tube welds on the right. These welds were made by the manual welder in the  left picture. These TIP TIG welds were made three to four times faster than conventional TIG. Thanks to the higher weld energy, the controlled dynamic wire feed, the exact wire to tungsten and wire to arc placement and less arc start / stops, the manual TIP TIG welds looked like orbital welds. Also with the tube welds note the weld cleanliness and minimal weld heat affected zones generated by TIP TIG. The fast travel rates is a great benefit for those concerned with controlling weld distortion and weld appearance.


INDUSTRIES THAT BENEFIT FROM TIP TIG WELDS: The bottom line, many companies are satisfied with the weld quality of their MIG or flux cored welds and for these companies why change?. Companies that will attain immediate benefits from the TIP TIG process are companies who weld code applications subject to NDT or destructive tests, companies who weld on costly alloys or companies that simply want to provide the ultimate in weld cosmetics without weld cleaning or spatter removal. Where as traditional automated and robot cold / hot wire TIG welds have been on many applications considered a sensitive process, weld shops will find that the automated TIP TIG process will be much more robust, dramatically decreasing down time and increasing both the weld quality and productivity. Note” TIP TIG is modified a hot wire TIG process and should have full acceptance from all code bodies.


Typical industries that can benefit from TIP TIG.

Power plants - Oil Platforms - Ship Yards - LNG Construction - Naval Vessels and Submarines - The Space and Aircraft Industries - Sub Sea Components- Petro Chemical - Refining - Waste to Energy - Industrial Processing - Pulp and Paper - Military Equipment - Medical Equipment - Food and Beverage equipment manufactures and any company that strives for optimum weld quality.





EVERY TWO MONTHS WE HAVE A TIP TIG WORK SHOP AT OUR FACILITY LOCATED
AT THE PHILADELPHIA NAVAL YARD. FOR INFO AND TO REGISTER
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.


 




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