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

TIP TIG is located at The Philly Navy Yard.
1901 Kitty Hawk Ave. Building 68 Philadelphia. PA.
Contacts at TIP TIG USA. Ed Craig and Tom O' Malley.

E-mail ed@tiptigusa.com or tom@tiptigusa.com

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

To witness the extraordinary weld results with TIP TIG.
We invite you to visit our TIP TIG demo location in the Philadelphia
Naval Facility and bring or send your weld samples.
Make an appointment: E-mail Ed@tiptigusa.com or tom@tiptigusa .com

COMPANIES WHO ARE GOING TO BE USING TIP TIG
OR ATTENDED THE TIP TIG WORK SHOPS .

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

AFTER SIXTY YEARS THE EVOLUTION OF
THE REGULAR TIG PROCESS IS NOW CALLED

WELDING ANY ALLOY IN ANY WELD ANY POSITION.
THE SEMI-AUTOMATIC MANUAL AND
AUTOMATED TIP TIG PROCESS SHOULD ALWAYS PROVIDE
SUPERIOR WELD QUALITY THAN ANY MANUAL
OR AUTOMATED TIG OR PULSED MIG WELD.



A 10 minute demonstration at our Philadelphia facility will indicate TIP TIG
will provide TIG welds typically 100 to 400% greater than the weld deposition
rates attained with any manual or automated regular TIG welds.





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




BENEFITS FROM "APPYLING WELD CONTROLS TO TIG WELDS".


In any organization that daily tries to attain optimum, uniform, manual weld quality
without concern for weld rework, it's especially beneficial when you can use a TIG
welding process in which you have "complete control of the weld consumables utilized" and there is only one TIG weld process that provides these weld controls;









Weld Heat is the prime root cause of most weld issues
with all alloy and none ferrous welds:


Irrespective of the weld process you are considering,
with Electrode Negative and the 50 to 400% greater TIG weld
deposition rates than regular TIG, the higher TIP TIG
weld speeds will create welds on any alloys that will
always ensure the lowest possible weld and part heat input.

SIX REASONS TO CONSIDER TIP TIG:

1] TIP TIG CREATES A UNIQUE AGITATED WELD POOL. IN CONTRAST TO TIG AND PULSED MIG, WITH TIP TIG
THERE IS LESS CONCERN FOR SLUGGISH ALLOYS AND TIP TIG SHOULD ALWAYS PROVIDE SUPERIOR WELD FUSION. WITH TIP TIG THERE SHOULD BE LESS INTERNAL AND EXTERNAL PORE WELD DEFECTS AND LESS REWORK ON ANY STEELS OR ALLOY WELDS.

2] TIP TIG PROVIDES MUCH FASTER WELD SPEEDS THAN REGULAR TIG. WITH THE
TIP TIG "EN" POLARITY THIS PROCESS SHOULD ALWAYS ENABLE THE LOWEST POSSIBLE WELD JOULES AND SMALLEST HAZ PRODUCING SUPERIOR MECHANICAL AND CORROSION PROPERTIES THAN THAT ATTAINED
FROM TIG OR PULSED MIG. TIP TIG SHOULD ALSO ENABLE LOWER PRE-HEATS AND REDUCTION OR
ELIMINATION OF INTERPASS TEMPERATURES.

3] TIP TIG IS THE WORLD'S MOST VERSATILE "ALL POSITION WELD PROCESS". IT'S A PROCESS WITHOUT THICKNESS LIMITATIONS AND CAN BE USED ON ANY ALLOYS.

4] WITH TYPICALLY 50 - 400% GREATER WELD DEPOSITION RATES THAN ALL
MANUAL OR AUTOMATED TIG WELDS, WELD SHOPS USING TIP TIG HAVE POTENTIAL TO DRAMATICALLY
LOWER THEIR WELD LABOUR COSTS.

5] IN CONTRAST TO THE REGULAR TIG PROCESS, THE TIP TIG FASTER WELD TRAVEL RATES DRAMATICALLY LOWER ARGON GAS COSTS AND THE TIP TIG WELD WIRE COSTS ATTAINABLE FROM THE WIRE SPOOLS OR
DRUMS SHOULD BE REDUCED.

6] TIP TIG IS ALSO SUITED TO WELD AUTOMATION WITHOUT THE USE OF SOPHISTICATED, COSTLY WELD EQUIPMENT LIKE AUTOMATED HEIGHT SENSING CONTROLS.

WHY CHANGE? MANAGERS, ENGINEERS, SUPERVISORS, & TECHNICIANS, HOW MAY WELD PROCESSES HAVE YOU COME ACROSS THAT WILL ENABLE WELD GROWTH OPPORTUNITIES FOR YOUR ORGANIZATION THROUGH WELD QUALITY, WELD PRODUCTIVITY OPPORTUNITIES?

During the next decade, the companies that are capable of consistently producing optimum code quality welds will see
weld growth opportunities in the following industries;

[1] Power Plants, construction and repairs.
[2] Oil & Nat Gas applications.
[3] Green projects fabrication.
[4] Defence / Aerospace applications.
[5] Medical industry applications.
[6] Electronic industry applications.

A common denominator with the above industries is the fundamental necessity for weld decision makers
to deliver daily, optimum weld quality with minimum weld rework. These companies will make weld on
costly alloys and applications. Many companies will consider two common weld processes. One process
will be the hundred year old SMAW (stick) process and the other process will be the traditional sixty plus year TIG process. Many of the companies that take on complex weld alloys and projects will use the
"this is the way we have always welded it philosophy" and use thr weld processes that have barely
changed in decades. Other companies will have management and engineers that understand the
importance of embracing new weld technology that can dramatically improve the weld quality and productivity produced.

WELD PROCESS CHOICES AND BENEFITS: For the last three decades the welding industry has seen few weld equipment or process advances that impact steel and alloy steels weld quality and productivity.
What has been evident in this time period is the introduction of endless weld equipment bells and whistles that provide few real world weld benefits while dramatically increasing weld equipment prices.


MIG SHORT CIRCUIT, MIG SPRAY, MIG PULSED, REGULAR TIG, HOT / COLD WIRE TIG, MIG STT - RMD -
CMT AND THE GAS SHIELDED FLUX CORED PROCESS, NONE OF WHICH CAN DELIVER THE ALL POSITION WELD / PART QUALITY ATTAINED BY THE TIP TIG WELD PROCESS.




FOR DECADES THE ACHILES HEEL OF TRADITIONAL
TIG PROCESS HAS BEEN "SLOW WELD SPEEDS".
Regular TIG has been considered the process of choice for attaining optimum weld quality. The TIG weld process
limitation has always been the "low deposition rates" that
can result in
very slow weld speeds. The slow TIG weld speeds have been primarily influenced by these factors.
[1] The TIG arc / plasma profiles and dynamics that result in a rapid solidifying small weld pool.
[2] The TIG electrode negative polarity that diffuses the weld
heat.
[3] The manual and automated TIG wire feed capability and
arc length restrictions that restrict both the weld wire and
weld current utilized.

The manual, low deposition TIG process requires the "highest manual weld skills" and those skills will
vary with each individual that picks up a TIG torch. To the chagrin of many weld QA managers and inspectors especially in the Power, Oil and Defence industries, manual TIG has been a process which you cannot apply "weld process controls" to the TIG weld consumables delivered to the welds.

The TIG manual wire feed restriction result in a process that typically has always produced the lowest
weld deposition rates and therefore regular TIG typically produces the slowest weld speeds that can result in in high weld heat input that may have a negative impact on both the welds and parts.

To meet both the manual and automated increased global TIG weld quality and productivity demands, it's logical to change the manual TIG process into a "semi-automatic TIG process" that enables increased
weld controls and productivity. The patented, semi-automatic TIP TIG process presented at this site is a
weld process that provides dramatic manual and automated weld quality and productivity benefits to all weldable metals and applications.


TIP TIG & CONSISTENT CONFORMANCE TO WELD PROCEDURE QUALIFICATION: A prime TIP TIG
benefit that should be of interest to any weld QA manager. The unique, semi-automatici, consistent fed TIP TIG wire feed rate and controlled wire placement in the small optimum TIG arc zone position enable
manual TIP TIG welders to provide consistent weld conformance to the key essential weld variables generated during any weld qualification. Its also beneficial when TIP TIG welders can improve the weld controls with the use of two hands (when required) on the torch, (see figure below).


TIP TIG & SUPERIOR WELD QUALITY WITH MUCH HIGHER
PRODUCTIVITY THAN REGULAR TIG: Irrespective of the alloys welded, in contrast to regular manual TIG welds and to the traditional automated Cold or Hot Wire TIG processes, TIP TIG should always provide superior weld
quality with increased hourly TIG weld deposition rates in the range of
50 to 500%, (100 - 400% more weld is the norm).

TIP TIG. SUPERIOR MECHANICAL & CORROSION PROPERTIES.
Think about the alloy weld benefits when considering TIP TIG. With most alloys welded with traditional TIG, the weld shop primary concern is
typically from the slow weld speeds and "high weld energy delivered".
With TIP TIG increased weld deposition rates (faster weld speeds) and the use of electrode negative (EN) and you have the opportunity to
dramatically reduce that weld heat to weld joules levels never before
attained with any other weld process. This has to result in superior weld
and part mechanical and corrosion properties.


IN CONTRAST TO REGULAR TIG, A SUMMARY OF THE PRIME TIP TIG WELD BENEFITS:

a] The higher TIP TIG weld deposition rates attained will result in much faster manual and automated TIG weld speeds. While regular TIG weld travel rates are typically 1 to 6 inch/min, with TIP TIG, typical weld
travel rates of 10 to 40 inch/min are readily attained. This dramatically reduces both manual and automated weld labour costs. You can also anticipate a reduction in the weld gas and weld wire costs, (weld wire no wasted wire ends and cheaper wire from spools or reels).

b] The TIP TIG electrode positive welds with the faster weld travel rates provides the potential to achieve
the highest possible weld quality with the lowest attainable weld heat input (lowest joules.) The results
can be superior mechanical and corrosion properties with less weld distortion for most applications.

c] The unique TIP TIG weld wire delivery consistently delivers the weld wire feed to the optimum arc and
weld pool position. Combine this with the constant fed weld wire and you have a consistent, uniform weld quality that can never be attained by regular manual TIG welder.

d] The TIP TIG process provides a constant fed weld wire that minimizes the required arc starts and stops required per weld joint. As we are all aware these are common weld defect locations.

e] The TIP TIG weld is agitated which slows down weld solidification reducing concern for sluggish alloys, improving side wall weld fusion and reducing porosity and contaminates in the welds.

f] Higher wire feed potential from TIP TIG enables more weld current to be utilized for applications
improving side wall weld fusion, reducing weld porosity and increasing the application potential to any
weld alloy and any part thickness.




A BRIEF DESCRIPTION OF TIP TIG: With the semi-automatic or automated TIP TIG process, the wire feed rate is constant and wire feed position into the optimum arc / weld position is fully controlled. The TIP TIG power source preheats the filler wire with resistance heating. A normal TIG power source provides the required weld current. The patented TIP TIG wire feed equipment is unique in that the four drive roll
induces a secondary high-speed linear oscillation that induces a unique dynamic onto the weld wire in the form of a vibration. The vibration passes through the weld wire into the TIP TIG weld agitating the weld.
The weld agitation slows the weld solidification and increases the weld receptivity to a constant fed weld wire.

Over a period of six decades there has been numerous weld procedures, weld practices and rules
established for the slow moving (high heat) traditional TIG process. Weld decision
makers should note that the faster TIG weld speeds (lower heat) and improved weld quality
attained from TIP TIG will alleviate the majority of the weld and metallurgical
issues that have been caused by the regular TIG process.



THE WELD PROCESS PROOF IS ALWAYS IN THE WELDS.



TIP TIG produces Titanium welds 100 - 500% faster than regular TIG
and produces superior quality welds with much less oxidation potential.




Take any other available commercial weld process and try welding 4 mm titanium
parts "without using a gas trailing shield" and attain this as welded optimum silver colour.

TIP TIG WELD ON 3/16 - 1/4 (4.8 - 6.4 mm) GRADE 2 TITANIUM: In contrast to the regular TIG process, when manual TIP TIG welding Titanium or any alloys the TIP TIG weld speeds will typically be 100 to 400% faster. Note the titanium TIP TIG weld size and approx. 24 inch/min (60 cm/min) manual weld travel speed verified by the U-TUBE second counter. The greater weld speeds from TIP TIG combined with electrode negative will in contrast to regular TIG or pulsed MIG always produce welds with lower weld heat reducing sensitivity to weld oxidization and TIP TIG welds should always create the smallest possible weld HAZ in the parent metal. Once you use TIP TIG onTtitanium or on any alloy parts you know you have a unique weld process that will provide extraordinary all position weld quality / productivity benefits. Visit section 2 (bottom of page) of TIP TIG for more Titanium info

The Titanium welds on this US army howitzer would have been better quality
with much lower weld issues and costs if TIP TIG had been the process of choice.

Welding Titanium or any Alloys. In contrast to regular TIG, when welding Titanium parts there are many weld benefits from TIP TIG. a] The higher TIP TIG weld speeds should produce the lowest possible weld oxidation potential b] The TIP TIG agitated weld pool produces superior side wall weld fusion with lower porosity and inclusion weld defects. c] With TIP TIG you have the potential to lower the TIG weld labour costs typically in the 100 - 300% range. d] With TIP TIG expect a dramatic reduction in your TIG weld gas and weld wire cost. Note. We are now making manual TIP TIG Titanium welds with 400- 500% greater weld deposition rates than that attained by regular TIG. For any weld engineer involved in welding any alloy applications and looking to optimise the weld and part's metallurgical properties, of all the available manual or automated weld processes TIP TIG will consistently achieve the best possible weld results. This is a statement that can be instantly verified at our facility in Philadelphia with a 30 minute TIP TIG weld demonstration on your application or test parts.

WITH TIP TIG WELDS MADE AT WELD SPEEDS 100 TO 400% FASTER THAN REGULAR TIG, THE WELD INDUSTRY NOW HAS A MANUAL AND AUTOMATED WELD PROCESS THAT WILL DRAMATICALLY LOWER ALL POSITION TIG WELD COSTS. THE AGITATED
TIP TIG WELDS CAN PROVIDE SUPERIOR WELD QUALITY TO REGULAR TIG AND THE LOWER TIP TIG WELD HEAT INPUT WILL PROVIDE UNIQUE WELD AND METALLURGICAL SOLUTIONS TO ALL FERROUS AND NONE FERROUS ALLOYS.

TIP TIG AND ALL POSITION WELD DEPOSITION RATES. How important is the following to a shop welding all position, code quality, pipe, plate or vessels? When welding 5G manual pipe fill pass welds, the regular manual TIG process when used for vertical up welds with a typical arc on time of 20 minutes per/hr will deliver approx. < 0.33 lb/hr. In contrast to regular TIG, the manual / automated TIP TIG process when used on all position pipe applications has the potential to always achieve superior weld quality with superior pipe "pipe root welds" made at weld depositions typically 50% higher than TIG and TIP TIG "pipe fill passes" with weld deposition rates 100 to 300% higher. On any typical flat and horizontal vee and fillet welds TIP TIG can deliver 200 to 500% more weld than regular TIG.

Note: Examine the TIG versus TIP TIG weld deposition data presented at this site, and if you have a moment view the TIG versus TIP TIG pipe videos.



Welcome. My name is Ed Craig. Many of you will know me from the 18 years of answering questions in the QA section of the Weld Design and Fabrication Magazine, or perhaps you have read one of my three books and 38 articles on MIG and Flux Cored Weld Process Controls. In the last few decades over a 1000 companies have purchased one of my manual / robot MIG / Flux Cored Best Weld Practices / Process Control Books and Training Resources. For those that like Engineering books perhaps you have read the Weld Section I wrote in that Machinery Handbook gathering dust on your book shelf. I have four weld patents in the power and fabrication industries and have in the last four decades provided TIG - MIG and Flux Cored Manual and Robot Weld Process Improvements and Process Control Training for close to a 1000 companies in 12 countries.

2009. I made a trip to Scotland to view the TIP TIG process. TIP TIG is the evolution of the conventional TIG process into the "semi-automatic TIG process". At that time TIP TIG had been used in Europe for a few years. In 2009 my business partner Tom O'Malley and I introduced this important weld process to North America and we have the exclusive rights for distribution of this product in North and S America and Australia. In a few short years I believe the TIP TIG process will be the world's prime welding process for all welds that require optimum weld quality or welds that benefit from low weld heat input.

Numerous global weld shops daily face the challenge of welding complex, heat sensitive alloys or welding applications with stringent code quality requirements. The challenging weld applications can be as varied as pipe for a Nuclear plant or the exhaust parts on the latest jet fighter. When welding demanding applications, managers strive to avoid costly weld rework, costly material replacement and unnecessary material handling or machining. In contrast to all other available manual or automated weld processes the semi automatic TIP TIG process should always provide the highest possible weld quality with the best weld metallurgical results.

If you are considering the Hot / Cold TIG - Plasma or Electron Beam process for your "automated welds" or you simply want to attain optimum consistent "manual" weld quality with good productivity and you believe in the importance of conformance with qualified weld procedures then please give consideration to the highly cost effective TIP TIG process.

A Logical Management Weld Objective:

"To be competitive in the weld industry we have to constantly embrace the evolving practical weld technology that "can provide real world weld benefits" This weld technology should daily deliver the highest possible weld quality at the lowest possible weld costs".




One of my TIG weld process control consultant projects in 2009 was for Cameron. This company is a Sub Sea Valve manufacturer located in Leeds UK. I was hired by Cameron management to figure out the root cause of their complex, Automated Hot / Cold wire TIG clad weld defects and provide the weld process improvement recommendations necessary for the Inconel clad welds made on large scale sub sea valve bores.

Note a common global weld management perspective. In the welding industry it's not uncommon for mangers and engineers who lack weld process control expertise to place the root cause of weld issues on the shoulders of the welders. The reality is traditional, automated Hot / Cold Wire TIG weld shop issues are typically influenced by;

a] Inappropriate weld process data.
b] Poor automated weld positioning equipment and lack of effective equipment maintenance.
c] Lack of process control training for all weld / management, supervisors and engineering personnel.
d] Lack of best weld practices and lack of appropriate manufacturing instructions on the shop floor.
e] Lack of weld management and engineer "Weld Process Ownership".
f] Hands off, unqualified weld supervisors and engineers.
g] A too common lack of effectiveness of the so called "pre-qualified weld procedures". Many of the pre-qualified weld procedures will be made on weld coupons that have little in common to the actual weld joints weld positions, torch angles and part thickness welded.
h] And of course the too common ingrained weld shop culture that's influenced by "this is the way we have always done it" mentality combined with the factors from A - H.




PRODUCT LIABILTY CONCERNS? THERE ARE WELD STANDARDS BEING INTRODUCED IN 2010 THAT WILL DEMAND ZERO WELD DEFECTS AND ONLY TIP TIG HAS THE POTENTIAL TO READILY ATTAIN THAT WELD QUALITY GOAL:

As weld companies strive to improve their weld quality and minimize the liability consequences of failed welds, at many companies the tolerance for internal weld defects is reaching unprecedented levels. In the oil, power and defence industries, demand for the highest possible weld quality has never been greater. One
of my UK clients when clad welding valve bores had a unique Sub Sea Weld Clad Quality Requirements that required "zero weld defects" on their clad machined weld surfaces.

In a weld shop it's one thing to have an NDT visual weld standard that allows specific weld defects and it's an entirely different situation when you have Inconel vertical up and horizontal clad bore welds that either require "x-rays or a machined clad weld surfaces" that must be completely free of any visible weld defects.

When using costly automated Hot / Cold wire TIG weld equipment and Arc Voltage Controls, on specific vertical and horizontal clad welds it's quite remarkable the amount of TIG weld pores, inclusions and lack of weld fusion defects that will be revealed.

Note: When a company talks about attaining zero or minimal weld defects, it's worthwhile noting that the future North American nuclear - coal - gas - oil power plants built to ASME weld code requirements will allow a variety of external and internal weld defects. It's also notable that there is only one weld process in the market place at this time that enables weld personnel to uniformly and consistently produce both manual / automated "all position" defect free welds on any alloys, and that weld process is TIP TIG.

TIP TIG SUPERIOR WELD QUALITY TO BOTH TIG &
PULSED MIG ON ANY WELDS IN ANY POSITION.

Click here to see the way TIG welds should be made.

ALL POSITION CODE QUALITY WELDS AND CONVENTIONAL WELD PROCESS CHOICES:

Most global companies who wish to produce all position “code quality welds” will in 2010 be
considering the following weld process options;

a] Traditional Manual TIG. This is a 70 year old process with weld pool issues that greatly restrict the manual weld deposition rate potential. Low weld deposition creates slow TIG weld speeds which is the primary influence on the high weld heat input generated on many manual and automated TIG welds. Manual TIG weld quality is primarily influenced by the "welder's skills". The manual TIG weld quality is also influenced by the frequent wire changes, (arc start / stops) the Inconsistent weld wire delivery and inconsistent wire to optimum arc placement. While manual TIG has the potential for optimum weld quality,
it's been a process in which it's difficult to attach weld process controls.

b] Traditional Automated Cold / Hot Wire TIG. These automated processes when utilized on vertical and horizontal applications or any low to moderate current applications can be extremely sensitive to to minor changes in the many variables that can influence the arc length and wire to optimum plasma placement. The automated TIG weld equipment will typically require Arc Voltage Controls. The "weld sensitivity" will on many welds restrict the wire feed rates to < 120 inch/min with weld speeds typically
< 6 inch/min. Due to the sensitivity of this process the automated TIG equipment will typically require Arc Voltage Controls (AVC). In contrast automated and robot TIG TIG welds will rarely require AVC and work
with much higher wire feed rates and faster weld travel speeds.

[c] SMAW: The 100 year stick process is a versatile process that's with the "use of a grinder" will deliver quality welds. SMAW is also a weld process with many electrode flux issues and therefore it a process in which no company can guarantee optimum first time weld quality without weld repairs. Common SMAW
weld defects are excess porosity, entrapped slag, lack of weld fusion, excess spatter, poor weld tie-ins,
undercut and the welder has often to deal with weld fume issues. SMAW is a weld process in which it's impossible to apply weld process controls.

[d] Pulsed MIG: The Pulsed MIG process has in the last three decades had many exaggerated electronic weld benefit claims. Irrespective of the pulsed MIG equipment purchased the reality of pulsed MIG is thanks to the Reverse Electrode Positive (REP) mode, a Pulsed MIG weld will result in high localized weld heat that often will result in a large HAZ. The Pulsed MIG process is wire stick out (WSO) sensitive and the small WSO changes which typically occur with most manual MIG welds can readily change the Pulsed MIG energy delivered to the weld by 10 - 30%. Also with Pulsed MIG the arc energy is constantly fluctuating between the peak to back ground current changes again influencing the weld energy delivered. When you combine the Pulsed MIG high weld deposition rates, (the greater the weld mass the greater the sensitivity to the variables that impact the weld fluidity) with the pulsed MIG WSO sensitivity and the peak to back ground current changes, the pulsed
weld results can be inconsistent arc energy that on specific applications especially on parts > 5 mm may result in lack of weld fusion and porosity.

[e] Gas Shielded Flux Cored: The flux cored process is far superior to the SMAW process, however when using gas shielded flux cored, irrespective of the welders skills, the weld shop will have to deal with slag inclusions, excess porosity, excess spatter, lack of weld fusion and excess fumes. And in the many miles of weld wire daily used there will be concern that the internal flux has not absorbed moisture and of course there will be "no guarantees the wire's flux composition and flux content are constant".



[f] Regular Manual / Automated TIG: < 2O10. In North America, when welding steels and alloys, the traditional TIG process has been the first process choice for most companies
wishing to minimize weld rework. Again the primary issues with the traditional TIG process;

[1] the inconsistent manual weld wire delivery to the weld pool,
[2] the inconsistent manual wire feed rates utilized,
[3] the manual and automated regular TIG weld dynamics that effect both the weld deposition potential
and limit the welding current that can be used,
[4] the inability to establish effective manual weld process controls with mmanual welding,
[5] the sensitivity of the process when used with weld automation.
[6] the numerous arc starts and stop (weld tie-ins) influenced by the manual weld wire changes.

Most manual TIG welds are made by welders using their own unique variable skills and weld techniques.
The traditional TIG welders will deliver inconsistent wire feed rates as the these welders with two hands dexterity manually feed their weld wire into a small, rapid solidifying weld pool. The regular TIG weld wire delivery variations, the frequent TIG weld start stops and very low TIG weld travel rates combine to have
an influence on both the weld and part integrity.

The electrode negative, regular TIG process dissipates most of it's weld heat into the welded part which offers a great weld heat sink, so why does the traditional TIG process put so much weld heat input into many parts? The inability of the rapid solidifying TIG weld pool to accept even moderate weld deposition rates results in a weld process that in contrast to the other common weld processes delivers very low deposition rates and very low weld speeds. Depending on the weld amps used, the low TIG weld speeds often lead to oxidized weldments with large heat affected zones (HAZ). Also depending on the metals
welded, the excess regular TIG weld heat will often be the prime cause of micro cracks, mechanical concerns, corrosion issues, excess weld oxidation or part distortion. It's also an important point to remind managers that thanks to the low weld deposition rates, the manual TIG process has always produced the highest hourly weld costs. It's also important to note that if most of your welds are small length welds there is little justification in purchasing a TIP TIG unit.

MORE ON THE REGULAR TIG WELD POOL AND IT'S ACHILES HEEL:

The fast solidifying outer weld periphery of the small regular TIG weld pool is drawn into the core of the fluid weld causing a rapid cooling gradient of the TIG weld that results in a fast freezing, small weld puddle which is not highly receptive to receiving filler metal.

To show the weld solidification sensitivity of a regular TIG weld pool, examine how the TIG weld surface tension can be dramatically influenced by "minute impurity changes in the weld wire chemistry".

For example when automated hot wire TIG welding with E316 "low sulphur" stainless as indicated in the above photo, (see note) the low sulphur content reduces the traditional TIG weld surface tension influencing arc wandering and the formation of weld defects and increasing the TIG weld sensitivity to weld wire delivery. When the amount of sulphur in the TIG weld wire is increased by a micro amount using fluxes or higher sulphur filler wires, a slight improvement occurs in the weld's surface tension and arc stability as seen in the regular TIG arc (top photo) on the right. .

Note: Photo and excellent article on 3I6 / sulphur / surface tension in Tube and Pipe Journal, posted on the web by Fabricator. com. The article by Barbara K. Henon, March 27, 2003 is called "Specifying the sulphur content of 316L stainless steel for orbital welding" When Barbara wrote her article she was not aware of the attributes of TIP TIG which at that time was available in Europe.

Question: Ed. in January 2007, we installed two AMET Inc. XM machine 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" which was made more difficult when utilizing new welding operators. Would TIP TIG help improve our sensitive, automated Hot wire process? Regards Frank at Diamond Power.

Answer. With TIP TIG Frank has the opportunity to use a TIG process without concern for weld sweet spots and he will also find he can dramatically reduce the amount of weld procedures his shop will require.


Even with the sensitivity and idiosyncrasies of regular TIG, this is a process that has for decades produced the highest consistent weld quality and therefore it's logical that improvements to the regular TIG process that enable a manual semi-automatic TIG process would have dramatic cost and quality impact for many in the welding industry.


In contrast to regular TIG, the TIP TIG process operates with a higher weld deposition and current range. The TIP TIG pre-heated weld wire and most releva the mechanical action on the weld wire creates a wire vibration that results in a unique "agitated weld pool' which dramatically changes the weld dynamics.

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

ADD THE SEMI-AUTOMATIC TIP TIG PROCESS TO A LOW COST ROTARY POSITIONER AND
YOU HAVE A FULLY AUTOMATED WELD PROCES THAT WILL DELIVER A WELD QUALITY
NOT ATTAINABLE FROM ANY OTHER CONVENTIONAL WELD PROCESS.

Application 17- 4PH Base deep J groove . ER630. 0.035 (1mm) wire. Over 60 weld passes.	The TIP TIG Weld Macro Reveals All.
This manual rotary multi-pass TIP TIG weld is made approx. 200% faster than manual TIG. TIP TIG would also be faster than the same welds made on most costly "automated" Hot wire TIG applications. Faster TIP TIG weld speeds result in a dramatic reduction in oxide formation and weld heat input.	On this 60 plus weld pass J groove weld joint used in an oil drilling application, we used no wire brushing between the weld passes and no grinding was used. Note the lack of weld pores or inclusions, the healthy side wall fusion and very small HAZ.

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

AS MANY EXPERIENCED WELD PERSONS ARE AWARE, 1960 TIG POWER SOURCES HAVE MUCH IN COMMON WITH THE TIG EQUIPMENT USED IN 2010.

A brilliant Austrian weld engineer, Siegfried Plasch invented the patented TIP TIG process. Siegfried found the key to dramatically improving manual and automated TIG weld quality and productivity was not to add sophisticated electronics to the TIG weld equipment. Siegfried's unique solution for the TIG process was to "physically change the TIG weld pool dynamics" Siegfried achieved this by imposing a mechanical action on the weld wire while it's fed from a MIG wire reel.

More than a 1000 TIP TIG units have been sold in Europe. At the 2008 Essen Weld Show, TIP TIG received the prestigious award for the show's most innovative welding process. In Sept 2009, TIP TIG USA (www.tiptigusa.com) took responsibility for the patent pending TIP TIG sales in North and S. America and Australia.

TIP TIG A PROCESS REVOLUTION FOR THOSE OPEN TO CHANGE IN INDUSTRIES
THAT STRIVE DAILY TO MEET THE HIGHEST POSSIBLE QUALITY WELDS.

TIP TIG CONSTANT CONTROL OF THE WELD WIRE FEED RATE AND PLACEMENT	NO OTHER PROCESS WILL DELIVER SUPERIOR MANUAL OR AUTO PIPE WELD RESULTS
Your choice, with or without a foot control and one or two hands on the weld torch.	Manual TIP TIG pipe welds typically 100 - 400% faster than TIG and the welds look like automated pipe welds

TIP TIG SUPERIOR WELDS ON ANY METAL ANY THICKNESS ANY POSITION.

With TIP TIG you take the slow inconsistent manual wire feed rates out of
the TIG process. With the "semi-automatic" TIP TIG process you have the
capability to control the weld wire and with one or two hands on the torch
produce superior weld quality than TIG while using MIG wire feed rates.





QA MANAGERS WILL BE GLAD TO KNOW THAT TIP TIG CAN SIMPLIFY THEIR WELD
PROCEDURE REQUIREMENTS AND DRAMATICALLY
REDUCE THE AMOUNT OF SHOP WELD PROCEDURES REQUIRED:

With TIP TIG, simply establish the weld current on the regular TIG power source and set the TIP TIG wire
feed rate to one of the four common TIP TIG wire feed settings that are applicable to most weld alloys
and all position weld applications.

Note: From any global weld code perspective TIP TIG is considered a "HOT or COLD WIRE TIG process" however due to it's unique wire feed action that changes the weld dynamics it's very different from any Hot or Cold wire TIG process you have ever seen.

Welding Chrome Moly Steels: None of the following weld processes, regular TIG - Pulsed MIG or Flux Cored can provide the all position weld quality that TIP TIG will deliver. TIP TIG weld agitation produces less weld pores and with less concern for sluggish alloys you should attain superior weld fusion. Thanks to the increased TIG weld speeds TIP TIG has the potential to lower weld distortion and produce welds with the best mechanical / corrosion properties.

If a picture is worth a thousand words, a video is worth a million.
View TIP TIG welding video sections at this site.

Welding complex, heat sensitive alloy applications.

When you provide the best all position weld quality at the lowest possible weld
heat input you have the ultimate weld solution for the world's most complex alloy welds.







COMPARE TIP TIG PIPE WELD DEPOSITION RATES WITH REGULAR TIG PIPE WELDS.

TIP TIG versus regular TIG Data.	TIP TIG.
PIPE ROOT: TIP TIG manual weld, improved uniform weld quality, typically 50 - 80% faster. PIPE FILL: Depending on the weld position, and wall thickness, manual TIP TIG is typically 100 - 400% faster while providing superior weld quality. HORIZONTAL FILLETS: Typically TIP TIG will be 200 - 500% faster than TIG for most fillet welds and superior weld quality. CONSUMABLES: TIP TIG dramatically lowers both weld wire and gas costs.
TIP TIG WELD PROCESS BENEFITS: [] TIP TIG one single optimum process for any metal, any weld and any weld position. [] In contrast to all processes, TIP TIG often requires only 3 simple common weld settings for most weld and alloy applications. [] On many stainless open root tank and vessel welds, with two sided TIP TIG, no back gouging, no grinding and often no high volume purge gas required. [] In contrast to all weld processes, TIP TIG will produce the least weld fumes and fume removal equipment on most stainless and alloy applications will not be required.	TIP TIG PROCESS BENEFITS: [] With TIP TIG you can weld with one or two hands with or without a foot control. [] Manual TIP TIG delivers a weld quality that's very similar to automated welds. Examine the manual TIP TIG weld uniformity and continuity with the videos and pictures at this site. [] TIP TIG provides the greatest weld heat control with the least oxidation, distortion and the smallest possible HAZ on any application. [] The TIP TIG agitated weld pools provide the potential to produce the lowest possible internal weld defects such as porosity, the agitation also reduce cracking potential and can produce lower weld stresses.

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

TIG & TIP TIG WIRE FEED / DEPOSITION RATES NEED CONSIDERATION
IN AN INDUSTRY THAT RARELY DISCUSSES WELD DEPOSITION RATES.

I recently did a survey of TIG weld personnel at some of the top engineering companies in North America. The companies included Westinghouse, General Electric, Siemans, Parsons and WSI.

The weld question. "Using a regular TIG 3/32 (2.4 mm) carbon steel or stainless wire, in a ten minute weld period what is the average manual wire feed length / rate deposited each minute?

The answer. The average regular TIG wire feed rate over an eight hour period was 8 - 10 inch/min. In the following table I converted the 3/32 (2.4 mm) TIG wire to an 0.035 (0.9 mm) wire to show the weld wire deposition (labour cost) differences between regular TIG and the TIP TIG process".

Real World 6 inch (15 cm) Pipe. 5G Position. Any steel alloys.

Six inch TIP TIG pipe welded by our Ausy Ray, (note not a welder).
Root to cap pass total time 25 minutes.
Note TIP TIG weld "uniformity and continuity". Minimum starts, stops. No defects.







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 3/32 wire feed rate. Green is conversion to 0.035 wire 10 inch/min (70 inch/min)	Manual TIP TIG Wire feed rate increase and labour cost reduction potential. 50 - 80%
[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 - 350%
[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 500%

5G pipe weld figures are real world. You will have some regular 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 weld automation.

TIP TIG. WELD PROCEDURES & WELD QUALIFICATION,
AN IMPORTANT POINT WORTH REPEATING:

Watch three highly skilled manual TIG welders manipulate the regular TIG weld wire through their weld glove and you will note the subtle skill differences, the different weld techniques and low wire feed rates delivered. The subtle TIG weld differences between each welder and the many arc start / stops is typically the cause of the weld defects found during NDT. The high weld heat input from the slow weld speeds is frequently the cause of defects. The slow weld speeds will often be the the root cause the welded parts mechanical or corrosion properties.

LEFT PICTURE TIP TIG P91 WELDS MADE BY SIEMEN.
With applications such as P91 or Duplex pipe welds in which there is a need to attain specific impact properties or ferrite levels, it may be difficult for shop welders to conform to the manual Stick or TIG weld procedure qualification and as a group uniformly and consistently attain the desired weld quality and mechanical properties without weld rework.

The TIP TIG semi-automatic process provides an opportunity to apply uniform weld process controls and improve the conformance to weld procedure qualification.

TIP TIG WELDING LARGE DIAMETER OR THICK WALL PIPE WILL TYPICALLY
DELIVER 200 TO 400% MORE TIG WELD FOR THE PIPE FILL PASSES AND THANKS TO
THE FASTER WELD TRAVEL RATES, THE WELD HEAT INPUT SHOULD BE LOWER.

THANKS TO THE UNIQUE TIP TIG TORCH DESIGN AND THE ONE HAND REQUIREMENT THESE TWO WELDERS CAN HAND THE TIP TIG TORCH TO EACH OTHER WHILE MAINTAINING THE PIPE WELD. FOR THOSE INTERESTED IN PIPE WELD QUALITY AND PRODUCTIVITY, TIP TIG WELD QUALITY SHOULD ALWAYS BE SUPERIOR THAN TIG AND ON THIS PIPE WELD THE WELDER HAS ACHIEVED A WIRE FEED RATE THAT IS 300 - 400% GREATER THAN A REGULAR TIG WELDER COULD ATTAIN.
One inch (25mm) wall pipe with the welder depositing the 0.035 (0.9mm) wire at 250 inch/min. 3.5lb/hr that's >400% more weld deposition each hour than most TIG welders will achieve on any pipe weld.

If you cannot view some of the videos at this site your IT dept may not be allowing UTube video viewing. Tell your
management it's difficult to "fly like an eagle and view new weld technology when encumbered by pigeons".

Ed wishes he had TIP TIG when he was in Thailand repairing Textron Tanks.

High Strength Low Alloy Steels: None of the following weld processes, regular TIG - SAW - Pulsed MIG or Flux Cored will provide the weld quality that TIP TIG. Also with high strength materials remember TIP TIG will produce the lowest weld heat, the smallest weld HAZ and therefore consistently produce the best mechanical properties.

THE PATENTED TIP TIG "EQUIPMENT BENEFITS":

[] The TIP TIG torch provides a constant fed wire feed always into the optimum arc / weld position.

[] The unique patented TIP TIG wire feeder provides a mechanical action on the weld changing the TIG weld dynamics.

[] The TIP TIG wire motion generates a vibration that runs through the weld wire into the weld pool. The wire vibration agitates weld pool providing many weld benefits.

[] The TIP TIG hot wire power source provides current to
pre-heat the TIP TIG Hot wire.

MANY WELD BENEFITS FROM TIP TIG:

IN CONTRAST TO REGULAR TIG & PULSED MIG, THE TIP TIG PROCESS CAN DRAMATICALLY REDUCE WELD DISTORTION:

[] IF YOUR WELDS ARE CRACK SENSITIVE THAT SENSITIVITY WILL BE REDUCED OR ELIMINATED.

[] IF YOU USE HIGH PRE-HEAT AND INTERPASS TEMPERATURES THOSE TEMPARTURES MAY BE REDUCED.

[] IF YOU WELD ALLOY STEELS LIKE DUPLEX, INCONELS, STELLITE AND STAINLESS THOSE WELDS WILL NO LONGER BE SLUGGISH.

[] IF YOU WELD ALLOYS SENSITIVE TO OXIDATION, TO MINIMIZE THE OXIDATION WHICH IS ESPECIALLY IMPORTANT ON MULT-PASS WELDS, THE TIP TIG WELDS WILL HAVE LESS OXIDATION.

[] IF YOU WELD PARTS AND X-RAYS REVEAL SMALL PORE DEFECTS THANKS TO THE TIP TIG WELD AGITATION THOSE PORES AND INTERNAL WELD DEFECTS WILL BE LESS.

[] IF YOU WELD PARTS AND THERE IS CONCERN FOR THE WELD OR PARTS MECHANICAL OR CORROSION PROPERTIES, THERE WILL BE LESS CONCERN WITH TIP TIG.

[] IF YOU ARE CONCERNED ABOUT ATTAINING CONSISTENT WELD FUSION, NO OTHER PROCESS WILL PROVIDE BETTER CONTROL OF WELD FUSION.

TIP TIG EQUIPMENT IS EASY TO MAINTAIN:
Maintenance supervisors will be glad to know that TIP TIG equipment does not utilize sophisticated electronics and the small portable TIP TIG weld units are readily adapted to most automated weld equipment including robots. TIP TIG utilizes both air and water cooled torches.

With TIP TIG you do not require a foot control for most welds, however if you feel the need for that additional weld control simply plug it in. Welders can make good use of their TIG skills with TIP TIG and use either one or two hands on the torch to provide the ultimate in weld control. With the constant fed wire feed and two hands on the TIP TIG torch, most manual TIP TIG welds should look like automated TIG welds.

Please Note: Do not confuse TIP TIG with any other global Hot / Cold TIG automated or manual TIG weld systems. Your North American weld personnel may say they have tried this technology, if they do they are confusing TIP TIG with other hot or cold wire manual or automated systems. The TIP TIG process has only been in North America since Sept. 2009 and this is the only available global TIG process that physically changes the TIG weld pool.

P91 Steels and other Creep Strength-Enhanced Ferritic Steels: None of the following weld processes, regular TIG - Hot / Cold wire TIG - Pulsed MIG or Flux Cored can provide the multi-pass weld quality that TIP TIG will deliver. Also TIP TIG will always produce the best mechanical properties due to the lowest possible weld heat input that comes from electrode negative with good weld speeds. Siemens reports that when welding P91 pipe with TIP TIG it attained the best weld results and mechanical properties it's ever achieved.

TIP TIG VERSUS TRADITIONAL HOT WIRE TIG: For those not familiar with the traditional automated Hot Wire TIG, this processes is typically used for "Automated TIG welds and clad applications".

To provide more energy into that rapid solidifying TIG weld, the Hot Wire TIG process typically has 50 to 100 amps delivered to the weld wire as it's fed to the TIG arc.

Hot Wire TIG provides only a partial weld energy solution to that fast solidifying TIG weld pool and therefore Hot Wire TIG will on many applications have restricted wire feed limits and will be considered a "sensitive process" poorly suited for most manual welds.

The problem with either the automated Hot and Cold Wire TIG process is no matter what type of sophisticated TIG power source is utilized, the automated TIG processes will produce welds with a small fluid weld area and the rapid solidifying TIG welds that have low surface tension. That surface tension is further influenced by the part thickness and the amount of TIG weld current that can be used for the weld.

The regular automated Hot Wire TIG process is especially sensitive to weld wire delivery when welding or cladding horizontal and vertical up welds, these are applications that are weld current restricted. For these welds, the traditional automated Hot / Cold wire feed rates will be typically limited in the wire feed range of 60 - 160 inch/min (1.5 - 4 m/min). To control the Hot / Cold Wire sensitive welds, automatic torch height equipment with Arc Length Voltage Controls is often necessary.

With automated TIG welds many companies will purchase costly automated TIG weld equipment to weld seams, deep groove applications or provide welds or cladding for valves and other components. From a weld quality perspective the automated, multi-pass Hot / Cold wire TIG welds may reveal small amounts of porosity, oxide inclusions and the occasional lack of weld fusion. With TIP TIG many of the costly automated welds produced could be done with superior weld quality at speeds 100 to 400% faster using a low cost rotary positioner or a simple Bug-o automated carriage.

Important Automated Weld Equipment Cost Savings. Before you consider spending a hundred to three hundred thousand plus dollars on automated equipment that utilizes TIG or pulsed MIG, let us show you the quality of the semi-automatic TIP TIG welds we will be able to attain for possibly a small percentage of what you intend to invest.

HAVE YOU USED HOT OR COLD WIRE TIG?
For those of you who have experienced CK and AICHI SANGYO TIG and traditional
Hot / Cold Wire weld units. These systems do not change the TIG weld dynamics
and cannot provide the manual or automated TIG weld quality and
productivity that the TIP TIG process enables.

Duplex. Super Duplex and Stainless Steels: None of the following weld processes, regular TIG - Hot / Cold Wire TIG - Pulsed MIG or Flux Cored will provide the weld quality that TIP TIG can deliver. With the unique weld pool agitation TIP TIG duplex welds are not sluggish and weld fusion and porosity issues should be less of a concern. TIP TIG can also be used for all root welds in any position. TIP TIG will dramatically lower weld heat input concerns, ferrite and impacts are easier to control. With TIP TIG both mechanical and corrosion properties are enhanced with a process that always provides the best possible weld quality with the lowest possible weld heat input. Ed: Ref Alberta Cold Lake / Tar Sands Duplex Weld Coupon results. We received the weld test results on the 10” duplex coupon that I welded in April. The customer reports that he has never seen duplex weld / ferrite / mechanical results as good as these. Jeremy TIP TIG Edmonton.

TIP TIG ONE PROCESS FOR THOSE FULL PENETRATION TANKS, VESSELS PLATE WELDS

IN A TIME OF WELD EQUIPMENT BELLS AND WHISTLES YOU WILL APPRECIATE
THAT TIP TIG PROVIDES BOTH WELD QUALITY AND WELD COST BENEFITS
THAT ARE EVIDENT THE FIRST TIME YOU USE THE EQUIPMENT.





VIEW WELD BENEFITS THAT ARE SIMPLY IMPOSSIBLE TO ATTAIN UNLESS YOU USE TIP TIG

CARBON STL TIP TIG 2 G PIPE ROOT.	CARBON STL TIP TIG 2 G PIPE FILL.
With TIP TIG attain the same uniform optimum root weld quality from 6 to 12 o'clock. Dramatically reduce weld starts / stops. View the cleaner less oxidized root and fill passes. WITH THE CONTINOUS WIRE FEED ALL TIP TIG ROOT WELDS ARE MADE FASTER THAN ANY TIG WELDER CAN PRODUCE. ROOT WELDS CAN BE MADE WITH OR WITHOUT A FOOT CONTROL Note: FOOT CONTROLS ARE RARELY REQUIRED WITH TIP TIG WELDS.	SUPERIOR SIDE WALL FUSION FROM THE TIP TIG AGITATED WELD WETTING & LESS OXIDIZED CLEANER WELDS GENERATE LESS FUSION AND PORE DEFECTS. WITH TIP TIG NO WELD START STOPS TYPICALLY REQUIRED FROM 6 TO 12 O'CLOCK. DEPOSITION RATES FOR TIP TIG FILL PASS WELDS ARE TYICALLY 100 - 400% HIGHER THAN THAT ATTAINED WITH TRADITIONAL TIG.

We also invite you to visit our Phily 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.

From Brian Dobben  - BSMET / WET
Welding / Mech Engineer.
LeTourneau University Alumni. 
Society of Manufacturing Engineering.

Jan 2010..A comment from Brian's Blog "Weld Sparks" A Note on New Weld Technology. TIP TIG is a remarkable highly modified one-handed TIG process that provides numerous weld benefits for every alloy, every industry, every Pulsed MIG - FCAW - TIG or SMAW application. All weld companies should immediately take a hard look at TIP-TIG. From welding aluminium boats to nuclear code work, from welding Titanium to Stellite, it does not matter whether manual or automated welds, TIP TIG will instantly provide superior weld quality while typically increasing TIG output by 2 to 5 times. An additional weld benefit, you should dramatically reduce weld heat input and also lower your weld consumable costs by 25 to 50%.  As you read this, TIP-TIG is drastically changing weld quality standards and weld process economics and quietly being adopted for many of the world’s most critical welding applications.



.
TIP TIG "SUPERIOR ALL POSITION WELD QUALITY".
In a 30 minute hands on demonstration at our Philadelphia facility the TIP TIG team can show you on any pipe, plate or manufacturing application how in contrast to any other weld process the TIP TIG process will provide superior,
all position TIG weld quality.

TIP TIG "INCREASED TIG WELD PRODUCTIVITY".
We are now establishing TIP TIG manual weld procedures that depending on
the component / pipe / vessel / plate wall thickness will in contrast to
traditional TIG welds typically produce an hourly, all position weld deposition increase of 100 to 400%. When welding vertical up or overhead welds, TIP TIG will compete with the weld times attained with flux cored and pulsed MIG and produce far superior weld quality without weld smoke as seen in the photo
on the left where the welder is TIP TIG welding 3/8 chrome steel vertical up.

TIP TIG "SMALLER EDGE PREPS FOR LESS WELD".
With TIP TIG you get the greatest all position side wall weld fusion potential from the higher energy (increased TIP TIG weld amps) and THE TIP TIG agitated weld pool. TIP TIG will provide weld cost
reductions on many applications by enabling a decrease in traditional pipe and plate VEE (40 - 50 degrees)
or or narrower J groove edge preps, and also on many edge prep welds you may be able to use less
preheat.

TIP TIG"LESS WIRE AND LESS GAS COSTS". With TIP TIG you will utilize MIG wire spools or reels.
In contrast to traditional TIG the short wire lengths and wasted wire ends with TIP TIG you can expect approx. a 20-25% reduction with the weld wire costs. Also as most TIP TIG welds are made at much faster weld travel rates than regular TIG welds you typically will require 20 to 50% less weld gas.

TIP TIG "ROOT WELDS AND VESSEL / PLATE PURGING". On many ROOT plate, tank or vessel
weld applications that require a gags purge the TIP TIG process enables manual controlled open root
"two sided welds". We can demonstrate this cost saving technique to your weld personnel. The two
sided TIP TIG root weld technique can on specific applications ensure "first time sound quality TIP TIG
eliminate gas purge costs.


LOW COST TIP TIG FOR YOUR CLAD WELD AUTOMATION:
It's this simple, you may be using traditional Hot or Cold Wire TIG
for your clad weld application, however please be aware these
processes cannot attain the weld quality or productivity achieved
by the TIP TIG process.

Many bore clad welds are also made with the inferior MIG short
circuit or the Pulsed MIG, Reverse Electrode Positive processes.
The 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 sluggish alloys,
[c] generate weld porosity or oxide inclusions,
[d] create weld spatter,
[d] produce poor weld tie ins.

Typical all position TIP TIG clad "weld speeds" on applications as indicated in the photo would be between 15 and 25 inch/min. TIP TIG clad welds frequently do not require costly Automatic Height Controls or 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. To watch a TIP TIG bore clad weld video click here.

North America: We are pleased to report that
Welding Services (Aquilex) - Westinghouse -
Exon and TI Fab one of the biggest Titanium
fabricators in the USA have now ordered TIP TIG units.

TIP TIG Sales / Technical Contacts. North - S. America
or Australia contact Ed Craig or Tom O'Malley.
E-mail. ed@tiptigusa.com. tom@tiptigusa.com.









10 FUNDAMENTAL REASONS TO VISIT PHILADELPHIA
AND VIEW THE TIP TIG PROCESS:

[1] MOST TIP TIG WELDS WILL TYPICALLY BE MADE 100 TO 500%
FASTER THAN REGULAR TIG.

[2] TIP TIG ALWAYS PROVIDES SUPERIOR WELD QUALITY THAN REGULAR
TIG, STICK, PULSED MIG, RMD - CMT OR FLUX CORED.

[3] IN CONTRAST TO REGULAR TIG THE FASTER TIP TIG WELD
SPEEDS WILL PRODUCE;

[] THE SMALLEST HEAT AFFECTED ZONES IN THE PARTS,
[] SUPERIOR MECHANICALS,
[] SUPERIOR CORROSION PROPERTIES,
[] LESS WELD OXIDATION,
[] SUPERIOR WELD FUSION,
[] LESS DISTORTION,
[] REDUCE WELD STRESSES,
[] LESS CONCERNS FOR CRACK FORMATION WITH ANY ALLOYS,
[] LESS INTERNAL PORES & MICRO OXIDE DEFECTS.

[4] WITH ALL POSITION WELDS, THE TIP TIG PROCESS PROVIDES SUPERIOR CONTROL AND ONCE LEARNT IS EASIER TO USE THAN ANY MANUAL PROCESS .

[5] NO OTHER MANUAL OR AUTOMATED WELD PROCESS CAN PROVIDE THE PROCESS CONTROLS THAT CAN BE APPLIED TO TIP TIG.

[6] ON MANY TIP TIG TANK, VESSEL, PIPE AND PLATE WELD APPLICATION YOU HA WIL HAVE THE ABILITY TO USE TWO SIDED TIP TIG ROOT WELDS. WITH THIS TECHNIQUE, YOU MAY NOT HAVE TO
FILL VESSELS WITH PURGE GAS, PROVIDE ROOT STEEL BACKING, DO EXTENSIVE ROOT GRINDING
OR BACK GOUGING.

[7] AS THE TIP TIG WELDS WILL BE THE CLEANEST YOU CAN PRODUCE, YOUR WELD SHOP WILL
HAVE LESS NEED FOR GRINDING DISCS AND STEEL AND STAINLESS WIRE WHEELS.

[8] TIP TIG WELD BENEFITS ARE ATTAINED ON ALL FERROUS AND NONE FERROUS ALLOYS.

[9] TIP TIG PRODUCES LESS WELD FUMES THAN ANY PROCESS. WITH THE OSHA 2010 NEW
STAINLESS FUME REQUIREMENTS YOU WILL NOT NEED TO PURCHASE EXHAUST EQUIPMENT
FOR MOST STAINLESS AND ALLOY APPLICATIONS.

[10] IN CONTRAST TO REGULAR TIG THE HIGHER WELD TRAVEL TIP TIG PROCESS PROVIDES WELDS THAT WILL RESULT IN LESS DISTORTION.

Austenitic - Martensitic - Ferritic Stainless Steels: None of the following weld processes, regular TIG - SAW - Pulsed MIG - Plasma or Flux Cored will provide the weld quality that TIP TIG will deliver. A ten minute demo will prove that when welding chrome nickel alloys, TIP TIG will always produce the lowest weld heat input, the least weld distortion, the lowest oxidation, the best weld fusion and the lowest porosity potential. The TIP TIG benefits lead to the lowest weld rework potential and TIP TIG should always deliver the best possible mechanical and corrosion properties.

 

 

SPACE - AIRCRAFT - POWER PLANT - OIL - DEFENCE - MEDICAL - ELECTRONIC INDUSTRIES

No matter how complex the alloys welded with the TIP TIG process there
will always be less potential for weld issues and part deformation.

Visit the TIP TIG Videos to view TIP TIG welding special alloys like Titanium, Hastelloy and Duplex.

WITH TIP TIG THERE ARE NUMEROUS WELD BENEFITS. THE ABILITY TO APPLY MANUAL WELD PROCESS CONTROLS, WELD ANY ALLOY IN ANY POSITION, PROVIDE LESS WELD HEAT, LOWER WELD DISTORTION, REDUCE WELD OXIDATION, REDUCE CONCERNS FOR SLUGGISH ALLOYS, ENABLE UNIFORM, CONSISTENT MANUAL / AUTO WELD QUALITY, REDUCE THE AMOUNT OF REQUIRED WELD PROCEDURES, DRAMATICALLY REDUCE WELD REWORK AND WELD COSTS.

THE SEMI- AUTOMATED "MANUAL TIP TIG PROCESS" WILL PRODUCE WELD QUALITY
THAT IS ATTAINED ON MOST COSTLY AUTOMATED TIG AND LASER APPLICATIONS:





TIP TIG "MANUAL" welding stainless tubes to sheet.
Better quality than TIG automation WITHOUT THE COST OF AUTOMATION.

Two hands controlling the TIP TIG torch and consistent, uninterrupted weld wire delivery.
No other manual weld process can apply this weld quality. Note the small HAZ. from
the low weld weld heat attained on this complex manual stainless application.




AN INDUSTRY DEDICATED TO CONSISTENT WELD QUALITY

TIP TIG is the only manual process in which effective "weld process controls" can be enabled.
Manual TIP TIG has the potential to always produce the highest possible weld quality and
with automated welds, TIP TIG will produce superior weld quality and higher
weld productivity than any automated Hot or Cold Wire TIG welds.






While many weld companies would be happy with a 10 - 15% increase in
TIG weld productivity, with TIP TIG we can show you how to attain 100 to 500%


Note weld cleanliness, the extremely small HAZ and no spatter.



IF YOU ARE ATTAINING CONSISTENT, OPTIMUM WELD QUALITY FROM
THE MIG OR FLUX CORED PROCESS, YOU WILL NOT NEED TIP TIG.

TIP TIG A WELD SOLUTION FOR SLUGGISH ALLOYS: In contrast with carbon steels and their fluid welds
in which the weld oxides and inclusion typically rise at a fast pace to the weld surface, with the sluggish composition found in the chrome nickel and nickel alloy welds, micro contaminates, oxide inclusion and
gas pores are more likely to become trapped in the welds providing unacceptable NDT results. The
sluggish nature of many costly alloys like duplex can also cause lack of weld fusion especially on all
position welds made on parts > 4 mm. Lack of weld penetration and internal weld defects can be a location for stress concentration. The EN TIP TIG process can provide higher more focused weld energy which when combined with the TIP TIG weld agitation is a great weld solution for all sluggish alloys.


TIP TIG A WELD SOLUTION FOR COMPLEX ALLOYS:
Are you concerned about Intergranular Corrosion - Weld  Sensitisation - Stress Corrosion Cracking - Hot Cracking - Cold Cracking - Hydrogen Induced Cracking - Transverse Cracking - Root Cracks - Toe Cracks - Crater Cracks - Micro Cracks - Carbide Precipitation - Impact Properties - Corrosion Issues - Controlling Ferrite Levels?

If your organization TIG welds Inconel Alloys - Invar - Stainless Alloys - Cobalt alloys - Molybdenum alloys - Titanium Alloys - Stellite Alloys - Duplex Alloys - Hastelloy Alloys - Haynes and Waspaloy Alloys HSLA steels or High Carbon steels or any cast components, the bottom line is the common denominator of all metallurgical weld issues is "weld heat".

With the TIP TIG process you will always attain the lowest possible weld heat input and therfore the potential to produce superior base metal mechanical and corrosion properties. If in the past you have been concerned about alloy's that are sensitive to weld crack formation we can guarantee you that the TIP TIG process will provide the least sensititivity to crack formation. If you oxy fuel hard face with alloys such as STELLITE 1 and very high pre-heat temperatures are required you could produce these same welds with TIP TIG and anticipate a 40- 50% reduction in both pre heat and interpass temperatures. It's nice to know that while you are providing weld solutions to the world's most complex alloys, in contrast to regular TIG the TIP TIG weld costs could be 100 to 400% less.

TIP TIG always provides superior
Weld Cast Repairs.

TIP TIG and Weld Cast Repairs: None of the following weld manual weld processes, regular TIG, Pulsed MIG or Flux Cored can provide the cast manual weld repair quality that TIP TIG will deliver. TIP TIG provides an agitated weld pool that enables the release of small pore defects and produces optimum weld fusion. In contrast to regular TIG, the semi automatic TIP TIG process does not have the numerous arc start and stops and the higher TIP TIG weld deposition rates results in a process that will produce the lowest possible weld heat input with much less time required for those weld repairs. In contrast to any other weld process with TIP TIG you will produce the lowest possible weld heat input, the least weld distortion potential, no weld slag, no porosity, no spatter, no lack of fusion, no grinding.. A 15 minute TIP TIG demo is all you will need to see that the TIP TIG process should always deliver the best weld results for your cast weld repairs. For a view of TIP TIG cast weld repairs click here.

A TIP TIG WELD FACT: ON MOST TIG APPLICATIONS IT TYPICALLY TAKES
TWO TO THEE TIG WELDERS TO DO THE WORK OF ONE TIP TIG WELDER.

PULSED MIG WELD CONCERNS. EXCESS WELD HEAT,
LACK OF WELD FUSION, POROSITY & INCLUSIONS.

ON MANY PULSED MIG ALL POSITION WELD APPLICATIONS > 5mm, YOU CAN ANTICIPATE LACK OF WELD FUSION, DISTORTION & POROSITY ISSUES.

In the last three decades many of the major global weld equipment manufactures focused on the installation of "electronic components into their MIG weld equipment".
The weld reality of pulsed MIG is the real world practical steels and alloy steels weld benefits attained from the pulsed equipment electronics has often been minimal.


After personally evaluating pulsed MIG equipment for approx. 25 years, from my perspective I believe that the Reverse Electrode Positive Pulsed (REP) MIG process is not capable of providing consistent, all position, optimum weld fusion on applications over >5 mm. The pulsed MIG weld issues become more of a concern if the alloys welded are considered "sluggish alloys" applications.

[] In contrast to REP pulsed MIG in which most of the weld heat is in the arc and weld wire, on the same welds attained by the electrode negative TIP TIG process, the weld heat has much greater dissipation into the base metals preheating the weld fusion area increasing side wall weld fusion potential.

[] The fluctuating pulsed MIG peak to back ground parameters provide a more inconsistent arc plasma
with lower arc temperatures than that attained with TIP TIG.

[] For steels and alloy steels, Pulsed MIG uses "reactive gas mixes" which increase oxide formation
which increases weld porosity / inclusion potential. TIP TIG only requires one gas "inert argon" and
TIP TIG wlds should always be cleaner.

[] With the Pulsed MIG process you will have "wire stick out (WSO) changes" during the weld. The small common MIG WSO variations can typically provide 10 to 25% changes to the weld parameters effecting the weld quality consistency. WSO is not an issue with TIP TIG.

[] In contrast to TIP TIG, manual pulsed MIG lacks the ability with manual welds to control the weld starts / stops and tie-ins data.

[] In contrast to TIP TIG, pulsed MIG requires much higher voltages than TIP TIG and the voltages
combined with the REP imparts much more heat in the weld's HAZ.

Note: Ed has been evaluating pulsed MIG for over 25 years and his 6OO page "Management Engineers
Guide to MIG" has over 100 pages on the issues generated by pulsed MIG. See also the pulsed MIG
section and the pulsed MIG equipment section at this site for extensive evidence and the root causes of
the pulsed MIG process and equipment issues.

Feb. 19 2010: E-Mail. PIPE ROOT WELDS: Ed. Reference our recent experience with Miller Pipe Pro MIG for pipe root / fill passes. In controlled welding conditions using the Miller "RMD short circuit process" for the root we would experience lack of fusion at the side of the root bead on P1 group 1 Carbon Steel pipes.  The root weld defects did not show up in radiographs but were obvious in the radius side bends. On the pipe ID the root bead was through, but narrow in spots. Although the weld defects were corrected at the PQT they came back with a change of MIG wire from a different wire manufacturer.

PIPE FILL PASSES: Mechanical testing of the pipe fill passes was then carried out for the same pipes with the Miller Pulsed MIG process available on the Pipe Pro power source. We decided on these pipes not to use the RMD process for the root passes and instead used TIG for the root pass. The TIG side bend tests had zero defects. For the fill passes we used the pulsed MIG process, however with this process  we had
had four coupons  with a first fill pass area beside the root bead that opened up". Ed the bottom line is we don't have a lot of confidence in either the Miller RMD process for the roots or the Miller pulsed MIG or FCAW processes for the 5G fill passes. The Miller sales rep claimed an apprentice welder can make pipe welds with this equipment with two days training. As you well know Ed, it's not making the pipe welds that is the concern, it's having many welders consistently first time passing the weld NDT requirements so we can avoid costly weld rework. It looks like we are heading back to TIG for both the root and fill passes, which brings up my interest in TIP TIG. Regards TW:

WELD STEELS AND ALLOY STEELS,
TIP TIG IN CONTRAST TO PULSED MIG:

	Volts	Opt Weld Transfer and AMP RANGE	Control of Arc Starts Arc Stops	Reactive Gas or special mixes?	Wire Stick out influence	Roots and all position capability	Heat sensitive alloys
REP PULSED MIG	23 28	100 - 300	No	Required	Negative	Not Capable	Poor
EN TIP TIG	12 16	20 - 500	Yes	Not required Less oxidation	N/A	First Choice	First Choice

STEELS AND ALLOY STEELS.
MORE DIFFERENCES BETWEEN TIP TIG & PULSED MIG:

[] TIP TIG in contrast to pulsed MIG enables much lower weld volts which combined with EN and moderate TIP TIG weld speeds can result in the lowest possible weld joules providing extensive weld / part mechanical and corrosion benefits along with lower weld distortion.

[] TIP TIG in contrast to pulsed MIG enables the widest welding amp range with low voltage which dramatically increasing the part thickness and "all position" weld application potential.

[] TIP TIG in contrast to pulsed MIG enables amp ramp up / down data that provides superior quality on any weld starts / stops and weld tie ins.

[] TIP TIG in contrast to pulsed MIG is not influenced by the common MIG wire stick out changes.

[] TIP TIG in contrast to pulsed MIG always provides superior weld fusion and superior weld controls with less internal pore and inclusion weld defects.

[] TIP TIG in contrast to pulsed MIG will always provide superior all position welds.

[] TIP TIG in contrast to pulsed MIG will produce no weld spatter.

[] TIP TIG in contrast to pulsed MIG has no concern for sluggish alloys.

[] TIP TIG in contrast to pulsed MIG can reduce pre-heat / interpass requirements. Also if you clad or hard face TIP TIG will produce less cracks.

[] TIP TIG in contrast to pulsed MIG uses straight argon and has the lowest possible weld oxidation potential producing cleaner welds on any parts.

[] TIP TIG welds in contrast to pulsed MIG will rarely require grinding or brushing.

[] TIP TIG in contrast to pulsed MIG on any 5G pipe application can weld the root with better control than regular TIG, STT, and RMD and TIP TIG will always provide superior all position fill pass weld fusion producing pipe welds with the lowest possible internal pore defects, welds with superior side wall fusion, welds with the lowest oxidation and welds that produce the smallest HAZ.

[] TIP TIG will produce less weld smoke than any MIG process.

On these 409 thin gage parts, Pulsed MIG
could never attain the weld quality of TIP TIG.


Left: Untouched 100% penetration TIP TIG weld made at 30 inch/min.
Right: Customers Pulsed MIG 100% penetration. Click for TIP TIG vide

E71T-1 Gas Shielded Flux Cored Wires.

No matter what the consumable mfgs claim, you know with flux
cored wires there will be no first time optimum weld quality guarantee.



WELD SHOP GRINDING - CLEANING AND WASTE:


Its' a shame in those weld shops that weld stainless or other costly alloys to
watch the welders get paid to produce the costly welds and then watch
the same welder pick up a grinder and remove much of the weld.



WITH TIP TIG IT'S RARE TO USE A GRINDER OR A WIRE BRUSH.

How often have you seen a long "manual" untouched 3 mm TIG fillet weld
with no weld oxidation, no start & stops and no colour change?

Manual TIP TIG 309 stainless fillet 25 inch long. Believe me this picture
does not do this weld justice. With a TIP TIG weld you should never need a
grinder. Too see actual finished TIP TIG FILLET weld video click here.

 

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 ARRIVES IN 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

 

TIP TIG is pleased to announce our first distributor in Australia
For TIP TIG Australian sales or weld demos contact;
Anthony Squire. 0459 150 338.
 www.proweldtraining.com
anthony@proweldtraining.com



Extensive TIP TIG data and
videos continue on Page 2.

Before you leave TIP TIG don't forget to visit www.weldreality.com
the world's largest web site on MIG and Flux Cored
weld best practices and process controls.