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Advanced TIP TIG Welding

At www.tiptigusa.com, you will find a weld process that always produces superior weld quality than TIG, and is 100 to 500% faster.


Welcome to the world's largest web site on MIG , Flux Cored & TIG Weld Process Controls & Best Weld Practices. The site provides the MIG - Flux Cored and TIG weld information required to attain the highest possible manual and robot weld quality, always at the lowest possible weld costs.

This web site was first established in 1997 by Ed Craig. Contact Ed. ecraig@weldreality.com

 

 

 

I have been evaluating weld process and weld consumables for more than four decades and I never saw a weld process that could consistently attain the weld quality, the mechanicals, the metallurgy and the productivity benefits that's possible with the TIP TIG process. The following are my personnel point of views on this very important process... Ed Craig.. 2015.


The evolution of the GTAW (TIG) process is TIP TIG:

TIP TIG WELD EQUIPMENT, PROCESS
COMPARISONS AND WELD APPLICATION BENEFITS:


[]TIP TIG 200 - 400% more TIG weld from each welder per/hr than TIG.
[] TIP TIG always superior weld quality than TIG.
[] TIP TIG superior metallurgical - mechanical properties than TIG.
[] TIP TIG less concerns for weld heat than manual TIG or Hot -Cold Wire TIG.
[] TIP TIG easier to use for any weld positions than TIG - MIG - Flux Cored.

 

 



Ed Craig... (weldreality.com).
During 2008, I went to evaluate the TIP TIG process in Scotland. UK. Darren Mathierson a canny wee Scots engineer provided a great weld demo and in five minutes, I saw what was the biggest break through in weld technology in my short 40 year weld career.

The unique TIP TIG patented weld process was invented by Siegfried Plasch, a brilliant engineer who lives in Austria.

I returned from Scotland and back in Philadelphia USA, I got together with my best friend Tom O'Malley. We, created an import company called TIP TIG USA. In 2009 with an exclusive agreement with Siegfried, we bought the first TIP TIG units to North America, and later we took this important weld process to Australia. Getting close to retirement, a few years later I sold the company to Tom, and Tom, may he rest in peace died well before his time in 2014.

If you weld code quality steels or any alloy applications you need to take a look at the TIP TIG process. When you call the TIP TIG USA to set up a demo or to send weld samples, ask for Nick or Patty, and tell him that an old fart called Ed sends his regards. However before you call, if you want real world weld info on this process, and especially want to know how TIP TIG compares with the other arc welding processes, take a few moments and continue to read this section.




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




TWO PRIME WELD REQUIREMENTS FOR MOST CODE AND ALLOY WELDS.

[1] Highest possible weld quality..

[2] Lowest possible weld heat..


TIP TIG ENABLES THE HIGHEST POSSIBLE ARC WELD QUALITY WITH THE LOWEST POSSIBLE ARC WELD HEAT. TIP TIG IS ALSO EASY TO USE AND PROVIDES EXCELLANT PRODUCTIVITY WITH IT'S LOW COST WELDS..

ONE WAY TO SHOW SOME OF THE EXTRAORDINARY TIP TIG WELD BENEFITS IS TO TAKE A QUICK LOOK AT WELDING COMPLEX TITANIUM ALLOYS, WHICH DURING THE WELDS ARE HIGHLY SENSITIVE TO OXIDATION AT LOW TEMPERATURES. TITANIUM HAS FOR DECADES CREATED MANY WELD CONCERNS AND TOO FREQUENTLY REQUIRED EXTENSIVE, COSTLY WELD REWORK.

THE MAJORITY OF TITANIUM WELDS ARE MADE WITH MANUAL GTAW (TIG) OR AUTOMATED HOT - COLD WIRE TIG. ALL THE TIG WELDS WILL TYPICALLY REQUIRE A CUMBERSON GAS TRAILING SHIELD.

The following information and video shows TIP TIG manual welding Titanium without the use of a Gas Trailing Shield. What is important about the TIP TIG video, is the TIP TIG weld demonstration video shows how easy it is with this important process to weld complex titanium alloys.

Note: When a process has attributes that are good for welding titanium, these attributes should be good for the majority of all alloy welds..

 




 

BETTER WELD QUALITY & EASIER TO USE THAN THE TIG..


TIP TIG WILL ENABLE SUPERIOR TITANIUM WELD QUALITY AND PRODUCTIVITY THAN THAT POSSIBLE WITH THE REGULAR MANUAL TIG, OR THE HOT - COLD WIRE AUTOMATED TIG PROCESSES.

As with welding most of the world's alloys, when welding Titanium, the use of TIP TIG should allways enable the highest possible arc weld quality with the lowest possible arc weld heat, both tremendous weld benefits.

Take the best TIG weld on any titanium application, and on any manual or automated weld the TIP TIG process should deliver superior weld quality with a nice weld cost bonus as the TIP TIG welds will be done typically 200 to 400% faster than the TIG welds.


LOOKING FOR WELDERS, OR WAYS TO REDUCE TIG WELD COSTS?

THIS GTAW WELD LABOR WELD COST FACT IS SO AMAZING, THAT YOU HAVE TO WONDER WHY SO MANY WELD DECISION MAKERS WOULD CONSIDER USING THE REGULAR MANUAL TIG OR AUTOMATED HOT - COLD WIRE TIG PROCESS.

TYPICALLY DURING THE WORK DAY, ONE TIP TIG WELDER WILL READILY ACHIEVE THE WELDS ATTAINED BY 2 TO 4 MANUAL TIG WELDERS, OR 2 TO 4 AUTOMATED HOT WIRE TIG APPLICATIONS.


As weld speed is a prime factor in the weld heat produced, in contrast to most manual and automated TIG welds, the higher deposition, much faster TIP TIG weld travel rates will dramatically lower the weld heat which of course reduces the concern for part distortion and weld oxidation, (porosity). Also with the TIP TIG process, the higher current potentail and unique weld puddle agitation, (slows weld solidification) changes the weld dynamics which both increases the weld fusion capability and reduces the welds porosity potential.

LET THE FOLLOWING VIDEO PROVIDE PROOF OF THE PROCESS:

Examine the "untouched" TIP TIG, TITANIUM, SILVER weld color in video (below). This color reveals the lack of oxidation. This TIP TIG weld is made by a first time user of the process on titanium plates and TIP TIG is used
without the use of a gas trailing shield.

Note: Depending on the weld application and code or NDT specifications utilized, Silver - Straw - Bronze - Brown can be acceptable for titanium welds.


Also with TIP TIG, the Titanium weld wire tip, (also sensitive to oxidation) is always in the TIG arc sweet weld and gas shielding spot, and even at the weld completion the Titanium wire tip is protected from oxide formation by the post shield gas flow. Apart from the Titanium wire savings you will achieve from using the MIG wire reels, think about the common TIG weld wire waste that you will prevent, no more oxidized, expensive alloy wire cut offs sitting in the scrap. Note: Typically 10 - 15% of regular TIG wire ends up as scrap.

Thanks to the higher TIP TIG manual / automated weld speeds, and of course the TIP TIG electrode negative polarity, at TIP TIG Tom and I made the following TIP TIG welds on Grade 2 Titanium, 3/16 (5 mm) parts without using a gas trailing shield.

When Tom and I worked on this Titanium part for one of the largest titanium fabricators in the eastern part of the USA, we achieved the bright (untouched) silver titanium weld without any indication of oxide contamination on the welds, or on the back side of the part.

While a trailing shields will likely be necessary for thin gage Titanium parts, I believe most Titanium welds on parts > 3 mm will not require trailing shields, and with TIP TIG, you can achieve weld quality and productivity that cannot be attained with any other process.

 



 

Titanium..Regular TIG versus TIP TIG.

IT'S IRONIC FACT, THAT THE HIGH TECH INDUSTRIES ARE TYPICALY SLOW TO EMBRACE NEW PRACTICAL WELD TECHNOLOGY:

Why in 2015 would any weld or fab shop, use regular manual TIG or Hot / Cold Wire TIG for their Titanium welds, when for more than a decade, the far superior, easier to use TIP TIG process has been available?

 

 

THE TITANIUM WELD VIDEO BELOW WOULD NOT BE POSSIBLE
WITH THE REGULAR TIG OR HOT / COLD WIRE TIG PROCESS.

 

TRADITIONAL ORBITAL TIG INFO WHEN
WELDING GRADE 2 TITANIUM.

MANUAL TIP TIG VIDEO
WELDING GRADE 2 TITANIUM
.

TRADITIONAL MANUAL GTAW, OR AUTOMATED HOT - COLD WIRE TIG AND TITANIUM WELDS:

As with the above USA Navy defence contract. Typically all position, manual or mechanized Titanium TIG welds on parts > 3 mm will be carried at very low weld GTA speeds in the
3 to 6 inch/min range.

THE LAST THING TITANIUM WELDS NEED IS HIGH WELD HEAT:

The low GTA weld speeds generate high heat welds, and therefore to minimize the effects of the weld heat oxidation on the weld, "gas trailing shields have been a critical weld requirement for most Titanium welds.

When alloy welds are sensitive to oxidation you know weld rework and weld porosity will be an issue.


TIP TIG SIMPLIFYS THE REQUIREMENTS FOR ALL ALLOY WELDS.

In contrast to regular TIG, depending on the part thickness, TIP TIG manual weld speeds on Titanium parts will typically be
10 to 30 inch/min.

The above 3/16 (5mm) Titanium lap weld, was made at a weld speed of
24 inch/min wihout a gas trailing shield.

If your organization uses regular manual TIG or Hot - Cold Wire TIG for automated titanium welds, you will be pleased to know that with TIP TIG, most manual or automated titanium welds will typically be done 200 to 400% faster and always should provide superior weld quality.

 

 

 



First time user welds Grade 2 Titanium,
Vee groove without a gas trailing shield.

 

I would have liked to see better prep on the plate surface and the use of a larger gas cup, however it's not bad for the welders first time attempt with the TIP TIG process on titanium plates. The TIP TIG weld is being made 250% faster than regular TIG and the TIP TIG weld quality is superior. Also to add to your weld cost reduction you will be using approx. 70% less weld gas than TIG and provide considerable savings with lower cost MIG wires and no costly wasted TIG wire ends.

 

 


FOR THOSE OF YOU THAT WORK WITH ALLOYS AND WORK IN THE DEFENCE, AEROSPACE, MEDICAL, POWER, OIL. GAS AND CHEMICAL INDUSTRY, REMEMBER, THE WELD / PART BENEFITS THAT TIP TIG CAN BRING TO TITANIUM WELDS, ARE THE BENEFITS ANY WELD DECISION MAKER COULD APPLY TO MOST OF THEIR ALLOY APPLICATIONS.


 

 

 


ITS 2016: MANAGEMENT IS WORRIED.

THE JOB REQUIRES 12 NEW GTAW (TIG) WELDERS.


THE BAD NEWS: The new welding job needs at least 12 skilled TIG welders, and the company is having a difficult time finding them.

THE GOOD NEWS: if any company decided to use the TIP TIG process rather than traditional manual TIG, that company would instantly enable a dramatic increase in it's hourly weld deposition rates and the company would find that instead of 12 TIG welders, to get the job done on time they would only need to hire 3 or 4 TIP TIG welders.

With the TIP TIG process, if the correct training is provided, any company with a few days of training could make someone "who has never TIG welded into a TIP TIG weld professional that could meet any ASME or other all position code weld quality requirements. Myself or TIP TIG can provide the training/

A manager that's not got his head buried in the sand may think.."Lets see, that's eight regular TIG welders we cannot find and now don't need, at an average yearly wage of $60,000 a year, with the decision to switch to TIP TIG we could easily save half a million dollars a year in labor, also the ability to out bid other TIG shops on future projects and the better quality welds with reduced distortion has great interest" ..
..

 

 

 

 

 

 

When did your welders last produce a "manual untouched" common, 309 stainless to steel weld that looked like this?

 

Above: 309 stainless to carbon steel 1/4 (6 mm). The 1/4 manual fillet weld is untouched. Note the small HAZ and lack of oxidation, both features reduce distortion and cleaning concerns. Without TiP TiG this weld would not be possible.



 

 

TIP TIG: IN CONTRAST TO ANY OTHER TRADITIONAL MANUAL OR AUTOMATED WELD PROCESS ENABLES A DRAMATIC IMPROVEMENT IN WELD QUALITY AND A DRAMATIC REDUCTION IN WELD HEAT (WELD JOULES) FOR ANY STEELS AND ESPECIALLY ALLOY APPLICATION:

Regular GTAW (TIG) utilizes Electrode Negative (EN) polarity which is good polarity for weld heat reduction as it dissipates most of the weld heat away from the tungsten tip into the part welded. However the Achilles Heel of the regular TIG, and the automated HOT - COLD Wire TIG process is these processes provide very low weld deposition rates, and these deposition rates create low weld travel rates that are typically in the 2 - 8 inch/min range. While the EN polarity takes the weld heat away from the tungsten tip into the part, its the slow TIG weld speeds that are generating the high weld / part heat input.

In contrast to regular TIG, the TIP TIG process through it's unique patented weld pool agitation, slows the weld solidification. This enables more wire to be fed into the weld pool. This change in the weld solidification dynamics enables much greater TIG weld deposition rates allowing for faster TIP TIG weld speeds. The typical TIP TIG weld speeds are in the range of 9 to 50 inch/min.

In contrast to all other manual weld processes, when you combine the higher TIP TIG weld speeds with it's EN polarity benefits, you should always attain
the lowest attainable Weld Joules. The TIP TIG lower weld heat input also produces welds with the smallest HAZ and therefore welds that produce the least possible weld distortion.

With the TIP TIG agitated welds, you reduce the potential for lack of weld fusion and with sluggish alloy welds, you also produce welds that should have the lowest possible weld oxidation. This enables alloy welds that will have the lowest weld porosity and the lowest potential for lack of weld fusion defects..

Note: In comparison to Pulsed MIG - Flux Cored, regular & Hot / Cold Wire GTA welds, with the TIP TIG process you can typically expect a weld joules reduction in the range of 50 to 200%.

TIP TIG is not new weld technology, it's been around for more than a decade, however TIP TIG is part of an industry in which process "change" is typically considered to be a a SWEAR word.

To be implemented, new weld technology that produces real world application weld quality and cost benefits, needs to be driven by progressive management, engineers and supervisors.. When the technology is not embraced, it's a usually a reflection of the lack of the weld decision makers process expertise.

 


 

 

TIP TIG if necessary, is also provided with unique automated
TIP TIG weld equipment. Automated info below..

 

 




2008: TIP TIG DRAMATICALLY REDUCES THE CHALLENGES ASSOCIATED WITH WELDING COMPLEX ALLOYS:

Numerous global weld shops daily face the challenge of welding complex alloys or welding applications with stringent code weld quality requirements. The challenging weld applications can be as varied as welding pipes or valves in a nuclear plant, turbine parts, sub sea valves, submarine parts or the exhaust on the latest jet fighter.


When welding demanding costly machined or prepared applications, managers and engineers always strive to avoid rejects, costly weld rework, costly material replacement and additional costly material handling and machining.

Weld managers, supervisors and engineers will be glad to know that in contrast to all other available manual or automated weld processes, TIP TIG is the easiest to use and will always provide the highest possible weld quality with the best metallurgical results for the applications.


COPPER TO STAINLESS.
On the right a 3/8 wall (9.6mm), 10 inch (25 cm) diameter Copper to Stainless pipe weld. This is a complex weld application with two alloys that have very different weld solidification temperatures.
[] TIP TIG, no pre-heat required.
Weld wire 0.035 (1mm), ErCuNiAI (Amptrode 46).
Note: The weld shown is untouched, and this was a first attempt with TIP TIG.


COPPER TO STAINLESS TIP TIG WELD BENEFIT. A PROCESS FOR BOTH THE ROOT & FILL PASSES: TIP TIG did both the root and the three fill passes. The complete TIP TIG weld cycle time including the root was approx 200 - 300% faster than that possible by the regular TIG welders.

COPPER TO STAINLESS TIP TIG BENEFIT: LOWEST WELD DEFECTS.
Note the fluid weld energy on these two alloys that typically produce very sluggish welds. The improved weld fluidity was possible as TIP TIG enables higher wire feed rates which allow for higher weld current than that typically attained with a TIG welder. Also the TIP TIG hot wire current and weld agitation further slows down the weld solidification providing superior side wall fusion and less pore defects than that possible with regular TIG, on either Cu or stainless. The customer appreciates a process that requires no weld rework.


COPPER TO STAINLESS TIP TIG BENEFIT: CLEANER WELDS - LESS FUMES. The weld as mentioned is untouched. Note the weld cleanliness and the lack of oxidation from the faster TIG weld speeds. These clean welds will have lower pore / inclusion defects than that possible with regular TIG. Also with TIP TIG you will achieve the lowest possible weld fumes.

REMEMEMBER TIP TIG IS A MANUAL - AUTOAMATED WELD PROCESS THAT BRINGS BENEFITS TO THE MAJORITY OF ALL ALLOY APPLICATIONS....


 

 



SOMETIMES COMPANIES THAT WELD ALLOY PARTS, WILL LOOK TO PURCHASE A COMPLEX AND COSTLY PLASMA, ELECTRON BEAM OR LASER PROCESS FOR THEIR WELD SOLUTIONS, AND IN MANY INSTANCES IT WAS NOT NECESSARY?

Any manager working with code quality welds or welding costly alloys will want to attain optimum, consistent, manual weld quality with good productivity. That same manager would likely also believe that the weld process selected should have the capability to attain consistent weld conformance with those pre-qualified weld procedures. Its common throughout the global weld industry for companies to sometimes go over board and purchase weld technology that they may not need.

With TIP TIG the addition of a simple turn table, an automated weld carriage, or a simple bore clad welder as shown below will lead to remarkable automated weld quality with very low weld heat input. For more on weld automation visit the TIP TIG Automation Section.

 

 



Why would any pipe shop use regular TIG, pulsed MIG or
flux cored to weld any code quality applications?.

You can weld pipe the old fashioned way (left), then grab the grinder to dig out the weld just put in or to remove the defects found later, or you can use a process like TIP TIG (right), less skills required, no spatter, no fumes, no weld rework. TIP TIG reduces inter pass and post heat concerns. TIP TIG is easy to use on both the pipe root welds and fill passes. Lets face it this process is so welder friendly, why not put two welders on the job?

[] TIP TIG FEATURE:
Less weld heat, than GTAW - Hot / Cold Wire GTAW or any MIG weld transfer mode.

TIP TIG BENEFITS.
Always superior mechanicals with less distortion and lowest possible weld fumes.

[] TIP TIG FEATURE:
Always lowest weld oxidation potential.

TIP TIG BENEFITS.
The cleanest possible untouched welds reduce clean up and should produce the lowest possible weld porosity.

[] TIP TIG FEATURE:
Highest GTA weld energy (higher TIP TIG wire feed rates enable increased current), with unique patented agitated weld pool that slows weld solidification.

TIP TIG BENEFITS.
Least concern for lack of weld fusion defects with all metals and especially with sluggish alloys like duplex, nickel and stainless.
Note: Always superior weld fusion than any pulsed MIG mode or GTA weld.

[] TIP TIG FEATURE:
Much higher manual - automated TIG weld deposition rates.

TIP TIG BENEFITS.
200 - 400% more weld production per-hour than the manual GTAW and Hot - Cold Wire processes.

[] TIP TIG FEATURE:
Automatic wire feed always into arc sweet spot and no foot control required.

TIP TIG BENEFITS,
Dramatically reduces the high weld skill requirements associated with most all position manual TIG welds and epecially with pipe welds.

[] TIP TIG FEATURE:
Four simple weld settings will weld most applications.

TIP TIG BENEFITS.
Easy to teach and and weld procedures are simple to establish.

Note if you intend to keep using MIG and flux cored for your code or alloy applications, please take a moment after you finish this section to look at my manual - automated Weld Process Controls - Best Weld Practices, self teaching and training resources. These resources will enable the highest posiible weld quality with theses processes at the lowest possible weld costs...

 

No brushing or grinding required. When the untouched pipe welds look like this, you know their will be no weld defects revealed by the NDT...

 

 

 

 

 

 

 

A few of the TIP TIG WELD EQUIPMENT BENEFITS:

TIP TIG Torch


[] The TIP TIG torch provides a "constant fed weld wire which is maintained in the optimum arc sweet spot, (impossible to achieve by any manual TIG welders.

[] The TIP TIG wire feeder provides a "unique, patented, mechanical action on the weld wire. The mechanical action AGITATES the weld pool changing the weld dynamics. The pool agitation slows the weld solidification enabling more wire to be fed into the TIG arc. The resulting increased wire, higher weld deposition rates provides for the use of higher than normal TIG weld current. The increased deposition also enables faster TIG weld travel rates.

[] The increased TIP TIG weld speeds dramatically lowers the TIG weld heat, while the increased weld current enables greater weld fusion potential. The increased weld energy and weld agitation also lowers weld porosity.

[] TIP TIG arc current is generated typically by a traditional 350 - 500 Amp, TIG power source that has features that can communicate with the TIP TIG torch


TIP TIG SIMPLIFIES WELD PROCEDURES, REDUCES WELD SKILLS & ENABLES EASY WELDER QUALIFICATION FOR CODE WELDS:


Photo right: The highly skilled manual TIG welder is required to sometimes operate a foot amp control, and manipulate and feed the TIG weld wire. Each manual TIG welder brings their own subtle skills to their welds, and you will note the influence of the welder's skill differences, in the weld appearance and weld quality attained.

The all position, TIG weld differences between each manual TIG welder, and the many arc start / stops required by the regular manual TIG process, are typically the prime reasons for traditional TIG pipe weld defects that will be revealed by NDT. Also the high weld heat input from the very slow manual TIG weld speeds is often the prime cause of cracks, distortion, oxidation and mechanical or corrosion issues. The high weld heat is also one of the reasons for inter pass temp concerns and post heat treatments.

Manually feeding the TIG wire at the right moment, and placing the TIG wire in the correct arc / weld spot and is a big part of the required regular TIG welder skills and is a learning process that typically takes extensive time, especially for all position welds.
The bottom line is these skills are not necessary with the mnaual TIP TIG process

 

2015. Outdated for more than a decade.

 

HOW MANY GLOBAL WELD SHOPS HAVE THEIR TIG WELDERS LIKE THE WELDER ABOVE USING HIGH SKILLS TO DEPOSIT ON AVERAGE TYPICALLY LESS THAN 1 LB/HR, WHEN FOR MORE THAN A DECADE, THE TIP TIG PROCESS HAS BEEN AVAILABLE, ITS EASIER TO USE, ENABLES 100 TO 400% MORE WELD, AND THE WELDS CAN HAVE SUPERIOR WELD QUALITY?

 

 

 



TIP TIG superior quality welds on any metal,
any thickness > 0.060 & any position welds
.

TIP TIG Welding

 

WHAT USED TO TAKE MONTHS OR YEARS TO LEARN CAN NOW BE LEARNT IN A WEEK.. WELCOME TO MORE TIP TIG WELD BENEFITS.

[] With manual TIP TIG welds, you take the slow, uncontrolled, inconsistent manual wire feed rates out of the TIG welding process, and also eliminate the defects which are found in the arc starts / stop locations.

[] With manual TIP TIG, their will be no no foot cramps as the welders do not require a foot control.

[] With manual TIP TIG, welders require much less welder skills. One reason is s the welder does not feed the weld wire and can control the torch with one or two hands, or use one hand for additional support as shown in the two photos above.

[] As the TIP TIG welder does not have to concentrate on feeding and placing the weld wire, or on a foot control, this enables the welder to provide more focus on the weld pool.

REDUCING WELDER REQUIREMENTS & WELD SKILL REQUIREMENTS CAN LOWER LABOR AND WELD REPAIR COSTS.

[] Regular TIG is a very low deposition process that on average produces around a pound of filler metal per-hour. Therefore when a company has to do TIG welds they may have to hire or use many welders to get the work out of the door. The regular TIG welders are considered highly skilled and are difficult to find. The more manual welders that required on the job, the greater the potential for weld differences and therefore weld defects. In contrast, with using TIP TIG, the weld shop can attain deposition rates that can increase the TIG weld production typically in the range of 200 to 400%.
A message to those weld decision makers that are aware that this year is 2015...

TIP TIG enables lower labor costs, enables highest weld quality and dramatically lowers the potential for weld defects..








Managers - Engineers and Supervisors take note:

HOW IMPORTANT IS IT WITH THOSE COSTLY ALLOY OR CODE APPLICATIONS TO PROVIDE WELDERS WITH AN EASY TO USE PROCESS THAT REQUIRES ONLY FOUR SETTINGS AND SIMPLE WELD PROCEDURES. A PROCESS THAT ENABLES BOTH THE HIGHEST POSSIBLE WELD QUALITY AND WELDS AT THE LOWEST POSSIBLE WELD COSTS.

MANAGEMENT, RATHER THAN BEING FOCUSSED ON FINDING WELD DEFECTS WHY NOT PREVENT THOSE WELD DEFECTS.

QA and Weld Management, with the recommendation to purchase the TIP TIG process, you could then advise the weld shop personnel that for the first time they will be able to utilize a process that is cost effective, and has the potential for the least weld defect formation.

 







FOUR TIP TIG MANUAL OR AUTOMATED AMP / WIRE FEED WELD SETTINGS FOR ANY STEELS OR ALLOY APPLICATIONS, ANY ANY WELD POSITION, FROM GAGE TO ANY THICKNESS.

Note: TIP TIG provides the required one day process control - best practice training with the TIP TIG purchase.

NO PULSED SETTINGS, NO WAVE FORMS AND NOTHING COMPLEX TO OPERATE:
To operate TIP TIG process, you simply set one of four common recommended weld current setting on the TIG power source and on the wire feed control set the one of the four common TIP TIG wire feed settings.

Note: From a global ASME weld code perspective, TIP TIG would be considered a "Hot Wire TIG process" however due to the patented "mechanical action" on the TIP TIG weld wire and weld agitation, TIP TIG welds are far superior to that possible with Hot Wire - Cold Wire and traditional TIG.

 

 





 

TIP TIG WELDING CHROME AND NICKEL STEELS:

No other process can even come close to the weld quality attained with TIP TIG on alloy applications..

None of the following weld processes, regular GTAW, regular MIG, Pulsed MIG or the Gas Shieded Flux Cored process can provide the manual or automated, all position weld quality that TIP TIG can deliver.


 

 

 

There are certain welds that you produce
that you know will never reveal defects.

What other manual / automated process do you
know can make any welds without weld defects?.





Complex - HEAT SENSITIVE Alloy Weld Applications.



When a process can provide the best possible, all position, manual or automated weld quality with the lowest possible weld heat and the lowest weld costs, management and engineers who figure out its time to stop "doing it the way we have always done it" will with their acceptance of TIP TIG, have a weld process that can provide the ultimate weld solutions for the world's most complex alloy welds.

 


 


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



I wish I had TIP TIG process when asked many years ago to manage a contract in Thailand for a USA company called Textron. The Thai Army had purchased the Textron, USA built Tanks, and many of the new tanks had developed numerous cracks before the tanks got of the Thai testing grounds. My MIG and flux cored repair welds were made on armor steels that were 270.000 tensile steel strength, and boy thats a metal that cracks like ice when subject to weld repairs in the vicinity of the original welds
. Ed in above photo..

 

 

 

Managers and engineers who are not stuck in the 1960s, or stuck in "this is the way we have allways done it" mode, would with weld process awareness, know that for arc welds (manual or automated) on complex alloys such as Jet Engine Castings to welds on Turbines or Nuclear parts, that they simply cannot do better than the TIP TIG process.

 


LIKE MOST ALLOYS OR CODE QUALITY WELDS, INVESTMENT CASTINGS WELDS AND WELD REPAIRS, WILL BENEFIT FROM AN EASY TO USE WELD PROCESS THAT CAN CONSISTENTLY DELIVER THE HIGHEST POSSIBLE WELD QUALITY, ALWAYS WITH THE LOWEST WELD HEAT:

Most alloy steels attain their mechanical or corrosion properties from the specific alloys utilized and the heat treatment provided, therefore when welding alloys, it's logical to use a weld process that can provide welds without defects, and welds that can allways provide the lowest possible weld heat..
.

 

 

 

 


IN MY ROLE AS PRODUCT / TRAINING MGR WITH AIR GAS - AGA - PRAXAIR (LINDE) AND LIQUID CARBONIC I EVALUATED WELD PROCESSES FOR MORE THAN THREE DECADES. IN THE EVALUATIONS, I NEVER SAW A WELD PROCESS THAT OFFERS SO MANY REAL WORLD WELD QUALITY - COST BENEFITS.



TIP TIG WIRE FEEDERS AND RELATED EQUIP WELD EQUIPMENT, EASY TO OPERATE, MAINTAIN AND REPAIR:

Maintenance supervisors will be glad to know that TIP TIG weld units are readily adapted to many modern 350 - 500 amp TIG power sources that have the ability to communicate with the TIP TIG torch.

TIP TIG is easilly adapted to automated weld equipment including robots. TIP TIG can utilize both air and water cooled torches, however as TIP TIG uses higher weld current than TIG with extended weld duty cycles, water cooled torches are most common.

With TIP TIG you do not require a foot control. Welders can make good use of their TIG skills with TIP TIG and benefit from the use of one or two hands on the torch. With the constant fed wire feed and two hands on the TIP TIG torch, most manual TIP TIG welds should look like and have the quality of 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 that simply cannot compete with this process. 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.


 

 

 

With TIP TIG you should expect the highest possible
weld quality with both manual and automated welds.

Using MANUAL TIP TIG this welders is making better quality welds, (TIP TIG practice welds right and application welds above) than what is typically possible on Water Cooling alloy tubes and using costly "automated" TIG tube weld equipment... Note the untouched weld quality and very small HAZ..

 

 

Below, common Tube to Plate welds. Manual TIP TIG can if required deliver superior weld quality - productivity than TIG weld automation, or of course you can use TIP TIG with auatomation..

 

TIP TIG ENABLES TWO HANDS ON THE TORCH, NO GTAW FOOT CONTROL REQUIRED. IMPROVED WELD QUALITY, UNIFORMITY AND CONTINUITY ON THE TUBE TO SHEET WELDS.

 

 

 

 


What did you say about those stainless weld fumes?


As Bechtel engineers and this TIP TIG welder found out at the Nuclear Waste facility, they finally have a process which will reveal no rework required with the X-Rays or other NDT that will follow.

TIP TIG. Duplex, Super Duplex, Inconel and Stainless Applications:

None of the following weld processes, regular TIG - Hot or Cold Wire TIG - Pulsed MIG or Flux Cored can provide the weld quality and metallurgical properties that TIP TIG can deliver.

SLUGGISH ALLOYS: With the unique TIP TIG weld pool agitation and higher current TIG capability per application, any alloys which typically have sluggish weld concerns and the resulting weld fusion and porosity issues should be less of a concern with the TIP TIG process.

DUPLEX: TIP TIG is the optimum process for welding Duplex pipe root / fill pass welds in any weld position.

DUPLEX: As TIP TIG dramatically reduces weld heat input, concerns about duplex ferrite levels or impact properties are greatly reduced. With TIP TIG ferrite levels and impact properties should simply never be a weld issue.

MECHANICALS: With TIP TIG both mechanical and corrosion properties will be enhanced from a weld process that always provides the best possible weld quality with the lowest possible weld heat input.

From Jeremy: TIP TIG. Edmonton.

Dear Ed: Reference the Alberta Cold Lake / Tar Sands Duplex Weld Coupon results. We received the TIP TIG 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. The ferrite results are reported below.

 

 

 

 


TIP TIG DUPLEX. "CONTROLLING FERRITE".

 

 

 


Note: As indicated in the above report, with this TIP TIG, "first time" attempt (no playing around) on an oil field, duplex application, the ideal Ferrite Volume percentage was consistently attained.

 

 

 

CONTROLLING FERRITE ON DUPLEX PIPE WELDS IS MADE SIMPLE WITH THE MANUAL OR AUTO TIP TIG PROCESS.

The volume percentage of ferrite present in duplex stainless steel clad metals will influence both the mechanical and corrosion properties.

Both strength and stress corrosion cracking resistance may be reduced when the FN is less than 30.

There will be is a loss of ductility and toughness of the clad metal when the FN is above 70 in duplex.

Duplex Welds. The Ferrite Number decreases with the rise in heat input and dilution. Pulsed MIG, regular TIG and flux cored will typically provide much higher weld heat input than a TIP TIG weld.

Consistent control of the Ferrite is essential to achieve optimum corrosion resistance and
mechanical properties yet the reality of pulsed MIG and flux cored when utilized, is a change in the gun angles or a change in the process weld wire stick out, can impact the ferrite volume.

FOR THOSE WELD SHOPS THAY HAVE TO ATTAIN CONSISTENT OPTIMUM FERRITE LEVELS WITH THEIR DUPLEX WELDS OR CLADD APPLICATIONS, SOMETIMES IT WILL BE A FRUSTRATING ATTEMPT WHEN THE PULSED MIG AND GAS SHIELDED FLUX CORED PROCESS ARE USED.

IN CONTRAST, ATTAINING OPTIMUM CONSISTENT FERRITE VOLUME IS SIMPLE WITH TIP TIG. WITH TIP TIG THERE ARE NO WELD FUME CONCERNS, NO WELD SPATTER, THERE SHOULD BE NO WELD REPAIRS REQUIRED, AND TIP TIG CAN DO BOTH THE ROOT TO ANY NUMBER OF
MULTI-PASS WELDS WITH ANY METAL IN ANY WELD POSITION.




 

TIP TIG WELD APPLICATION:

" SMALL DIAMETER" STAINLESS TUBES TO SHEET WELDS.

For the small diameter stainless tube welds shown on the right, the easy to use TIP TIG process enabled the welder to use "two hands" on the light weight torch to provide ultimate manual control of the TIG torch as it went 360 degrees around the small diameter tubes.

Heat exchanger material: 1.4571 Tube Diam 3/4 inch (18mm). 2 layer welds required. Welds must be defect free. TIP TIG Weld time: 14 sec/weld.

On these TIP TIG tube to sheet welds, note the weld tail on each weld. The tail was a customer requirement to keep arc starts / stops out of the welds. This manual TIP TIG welder benefited from using two hands on the torch and the controlled, constant wire feed rate generated an automated weld appearence. The welds were done 2 times faster than regular manual TIG. The resulting TIP TIG weld quality was superior to the manual TIG and pulsed MIG welds previously applied. The TIP TIG welds produced the lowest distortion and were 100% defect free. One thing companies need to consider instead of purchasing costly orbital, automated equipment for applications like this, they can get the same quality and productivity with a manual welder and the TIP TIG process..

 

 

 





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, consistent, optimum root weld quality from the 6 to 12 o'clock positions.

With TIP TIG you dramatically reduce weld starts / stops, and will attain cleaner, less oxidized root and fill passes.

With the continous wire feed, all TIP TIG root welds are made 50 to 80% faster than regular TIG, while the fill passes are typically 100 - 400% more wire.

 

SUPERIOR SIDE WALL FUSION FROM THE TIP TIG AGITATED POOL PLUS HIGHER AMP = INCREASED WELD WETTING.

Less oxide formation leads to cleaner welds with less pores and inclusions. With TIP TIG root - fill passes, the reduced weld start / stops typically required from 6 to 12 o'clock enable a weld quality uniformity impossible to attain with regular manual TIG or pulsed MIG.

 

 

While GTAW requires the highest manual arc welding skills, TIP TIG dramatically reduces those GTAW skills. TIP TIG, no foot control required, no feeding a wire at the right moment in the optimum arc plasma position.

As a litthe bonus. TIP TIG typically delivers 100 - 400% more GTAW weld per/hr, and with superior weld / part quality than possible with GTAW.

 

It's nice to use one hand.
Reduced concern for Stainless Weld FUMES?


 


 

WHO BENEFITS FROM WELD REWORK ON COSTLY ALLOY PARTS?

Austenitic - Martensitic - Ferritic Stainless Steels: None of the following weld processes, regular TIG - Pulsed MIG - Plasma or Flux Cored can consistently provide the weld quality that can be attaines with TIP TIG. A ten minute demo will prove that when welding chrome nickel alloys, TIP TIG will always produce the lowest possible weld heat input, the least weld distortion, the lowest oxidation, the best weld fusion and the lowest porosity potential.

Most alloy parts are expensive and TIP TIG enables the lowest possible manual or automated weld rework.

 




Duplex welds are simple with TIP TIG.

You will see weld cleanliness and weld colors you have never seen before.
Untouched, Super Duplex, MANUAL TIP TIG, 1/4 Fillet.

 

 


 

 

2009: Some of the slow to wake up manufactures of brewing, beverage, chemical, oil, LNG tanks and vessels are finally getting to be aware of of the cost benefits of TIP TIG.


STAINLESS - DUPLEX - NICKEL ALLOY TANKS AND VESSELS, TIP TIG WILL PROVIDE SUPERIOR ALL POSITION WELD QUALITY AND THE WELDS ARE EASIER TO APPLY THAN WELDS MADE WITH MIG - TIG SMAW OR FLUX CORED..

Due to low deposition rates, regular TIG is rarely considered for large scale weld fabrications and pulsed MIG and flux cored will typically provide both costly to repair weld defects and always weld fume concerns.

TIP TIG is suited for any all position welds from the root pass to the finished welds. Note picture left in which TIP TIG is used for welding vertical up 3/8 (9.6mm) duplex plates. Note: No with welder on the left the reduction in weld fume concerns, and of course with all alloy welds the lowest weld distortion potential is achieved.


TIP TIG LESS SKILLS AND INCREASED TIG WELD PRODUCTIVITY".

With typically no more than two weld settings required for any weld application, the TiP TiG process will in contrast to traditional TIG welds, typically produce an hourly, all position weld deposition increase on parts > 0.060 of of 100 to 400%.

As no weld grinding or rework is required, when welding any vertical up or overhead welds, TIP TIG can compete with the weld times attained with both flux cored and pulsed MIG, always with the lowest possible weld fumes.


TIP TIG also enables "reduced VEE OR J EDGE PREPS.

In vee and J groove welds, side wall weld fusion is always a concern especially with sluggish alloy welds. With the agitated (slow weld solidification) TIP TIG welds that usually use higher current than TIG welds, you get the greatest "all position side wall weld fusion potential" on any weld.


THE REASON TIP TIG REDUCES SIDE WALL WELD FUSION DEFECTS.

The TIP TIG process enables increased TIG weld amps.
TIP TIG provides a unique, patented agitated, slower solidifying weld pool.
TIP TIG weld wire is preheated.
TIP TIG is EN polarity provides more heat into the metal adjacent the welds, in contrast, MIG and Flux cored are Reverse Polarity most of their weld heat goes to melting the weld wires.

With the unique TIP TIG weld attributes, extensive weld cost reductions may be enabled on Groove welds. Both VEE - J grooves angles can typically be dramatically decreases sometimes reducing the filler metal in the range of 25 to 60%.

Also on many alloy welds with TIP TIG you may be able to use less weld preheat and eliminate weld post heat and spend have less time or concern for interpass temperatures.


TIP TIG RESULTS IN "LESS TIG WIRE AND LESS WELD GAS COSTS".


In contrast to traditional TIG which more costly short weld wire lengths too often with wasted wire ends, In contrast to TIG, with TIP TIG, you will utilize lower cost MIG wire spools or reels. with TIP TIG you can expect approx. a
15 - 25% reduction with your weld wire costs.

As most TIP TIG welds are made at much faster weld travel rates than regular TIG welds you typically will require 20 to 60% less argon weld gas.


TIP TIG "SOME ROOT WELDS WITHOUT A COSTLY GAS PURGE".


On many ROOT plate, tank or vessel alloy weld applications that require a gas purge, the TIP TIG process may (not suited to all applicationss) enable manual controlled open root "two sided welds". The TIP TIiG company will demonstrate the Two Side Root Technique. The two sided, two operator TIP TIG open root weld technique can on specific applications ensure "first time sound quality root welds that are made without root backing, without back gouging, without grinding and of course without gas purge costs.




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


10 REASONS TO VISIT THE TIP TIG FACILITY IN NEW JERSY (NEXT TO PHILY) & VIEW THE TIP TIG PROCESS.

[1] LESS WELD LABOR COSTS:
Most TIP TIG welds will typically be made 100 to 400% faster than regular TIG. Smaller vee preps will also dramatically reduce the weld costs.

[2] LESS WELD REWORK COSTS. TIP TIG always provides superior weld quality than regular TIG, STICK, PULSED MIG, RMD - CMT OR GAS SHIELDED FLUX CORED.

[3] SUPERIOR METALLURGICAL OR MECHANICAL PROPERTIES: In contrast to regular TIG, the faster TIP TIG weld speeds will produce;

[] The smallest weld HAZ.
[] Superior Mechanicals.
[] Superior Corrosion properties.
[] Less Oxidation for cleaner welds.
[] Superior Ffusion any applications.
[] Less Distortion.
[] Lower Stresses.
[] Less concern for Cracks.
[] Less concern for internal weld Pores and Inclusions.
[] Always the lowest Fumes.

[4] EASY TO LEARN AND USE..With all position pipe welds, the TIP TIG process provides superior
control and once learnt is easier to use than regular TIG. Note the wonderful benefit of producing the highest possible weld quality with no spatter or weld fumes, (on right)..

[5] EASY TO CONTROL.. No other manual or automated weld process can provide the weld quality and the "process controls" that can be applied to the
TIPTIG process.

[6] UNIQUE WELD ATTRIBUTES On many TIP TIG tank, large vessel, plate weld applications you may be able to use the "two sided" TIP TIG process on open root welds. .

[7] CLEANEST WELDS: As the TIP TIG welds will be the cleanest you have ever produced, your weld shop can cut back on the purchase of grinding wheels, stainless brushes etc.

[8] EASY TO ATTAIN ALLOY WELD PROPERTIES: Highest possible weld / part mechanical / corrosion properties.

[9] LOWEST POSSIBLE WELD FUMES.. TIP TIG produces less weld fumes than any other process. With the OSHA stainless (chrome) fume requirements you will not need exhaust equipment for most stainless, nickel and high alloy welds.

[10] LOWEST POSSIBLE WELD DISTORTION.. In contrast to regular TIG, the higher weld travel rates attained from TIP TIG
will enable less weld distortion.

 

 


 

 


 

NUMEROUS QA WELD AND PART BENEFITS FROM TIP TIG.

[] CONTROLS: With TIP TIG the weld shop will have the ability to apply the most effective manual Best Weld Practices and Process Controls achieving greater conformance to weld procedure requirements.

[] LESS SKILLS: TIP TIG REQUIRES LESS SKILLS THAN MIG, FLUX CORE OR REGULAR TIG FOR ALL POSITION WELDS.

[] ONE PROCESS: For code quality welds, the TIP TIG welder can use a single weld process for any weld, any alloy and any weld position.

[] SIMPLE: TIP TIG USE FEW AND SIMPLE WELD PROCEDURES.

[] LOWEST HEAT: The TIP TIG welds will provide the lowest weld heat which will provide numerous weld benefits for all heat sensitive weld alloys.

[] DISTORTION: TIP TIG ENABLES THE LEAST WELD DISTORTION.

[] WELD CLEANLINESS: TIP TIG enables the lowest weld oxidation.

[] METALLURGY - MECHANICALS: TIP TIG PROVIDES SUPERIOR MECHANICAL / CORROSION PROPERTIES.

[] SLUGGISH ALLOYS: TiP TiG reduces the weld fusion concerns with alloys that produce sluggish weld solidification.

 

 

 

TIP TIG AND WELD AUTOMATION INFO...


While many companies spend thousands or millions on the robots, weld automation and fixtures, I often wonder with many of the companies I visited, how much consideration went into the actual weld process / consumable selection.

With many weld shops, the weld process selection is greatly influenced by the weld NDT (or lack of) requirements. There typically will be a dramatic MIG - TIG weld quality differences delivered from a Truck weld part supplier, than the MIG - TIG weld quality delivered in a pipe shop.


Note: A weld professional with weld process control expertise would never be concerned about the weld quality requirements of any application, as evey weld that they are responsible for, would be delivered always with the best possible weld quality,

2009: When "extraordinary weld quality" is required automation is added to the weld process. For decades, the the regular TIG, Hot Wire TIG and Cold wire TIG would be considered or requested. These GTAW processes when used with many automated applications were extremely sensitive to arc length variations. Also the low GTAW weld deposition rates that resulted often produced very slow weld travel rates with high part heat.

With robot welds, when filler metal was required for the weld with Hot Wire or Cold Wire GTAW, the robot would often be prone to more down time than up time, and th robot GTAW combination depending on the application would often be considered a "high risk" weld application
.




P
ROBLEMS WITH TRADITIONAL AUTOMATED GTAW (TIG) WELDS:

To enable consistent melting of the traditional constant fed cold or hot TIG wire into the small, narrow TIG arc plasma, there are many essential weld variables that have minimal room for change or error.
A few of the variables:
[] arc current,
[] arc length,
[] tungsten condition,
[] wire feed rate,
[] weld travel speed,
[] weld wire placement.
[] wire to tungsten distance.




With the conventional, automated hot or cold TIG welds, if the weld wire is not maintained at the correct distance from the tungsten tip to work, or the wire is not aligned in the same plain as the tungsten tip, the resulting weld energy in the small weld pool can dramatically change and the weld may end up being more sluggish and result could be lack of weld fusion or an increase in porosity. Of course if the wire gets too close to the tungsten this can result in tungsten contamination.

With many automated TIG applications, Automatic Height Control will be used to control the tungsten to work distance . It's interesting to note that companies who do a lot of automated hot and cold wire TIG clad welds, will run the 0.045 alloy wire with horizontal / vertical up welds typically at wire feed rates of 80 to 150 inch/min (1 - 2 lb/hr).

The conventional automated TIG process utilizes both Cold Wire and Hot Wire in which the weld wire is preheated with low amps. The automated TIG "cold wire" process is frequently used for challenging welds in which slower wire feed or slower weld speeds are beneficial to the application. Using the conventional TIG "hot wire" process, the weld shop can produce automated weld quality with occasional weld defects and poor weld deposition rates, however if you have ever established the weld data for traditional hot or cold, automated TIG welds, you would be aware of the frequent weld, equipment and consumable issues that are generated from feeding a small diameter weld wire at a constant rate into the small narrow target in the weld pool, between the tungsten and the work.

Providing an automated Inconel TIG clad weld in the bore of a valve, or making a nuclear mechanized TIG weld repair on a failed valve and at the other end of the spectrum watch a robot struggle with TIG cold wire weld on the edge of a stainless or aluminum electronic control cabinet. One thing most of these automated TIG weld - clad applications will have in common
is daily weld quality, consumable and equipment issues.


Note: The use of the traditional hot wire process for "manual TIG applications" was not considered practical.





2009: Application: Deep Sea Valves. Traditional
Automated TIG
, Inconel Clad Bore Welds.

Deep sea valves may require Inconel or stainless clad GTAW welds in the bores and other locations. The automated clad bore welds may have to meet exacting maximum clad (5 - 10% iron) weld dilution requirements.

To meet the highly critical clad weld standards which usually require "Defect Free welds" on the the finished machined clad weld surfaces, you will find many weld shops will struggle to maintain weld quality consistency in their automated Hot and Cold wire welds.

With the high clad weld quality requirements for Sub Sea Valves, the clad welds usually have high weld repair, machining and material handling cost consequences. It's common in the facilities that do these welds to find many engineers and managers stuck in that "THIS IS THE WAY WE HAVE ALWAYS DONE IT MODE" and when weld quality issues arise, for the root cause, they will look to weld shop personnel as a prime cause of the daily automated TIG clad weld issues.

Rather than "people issues" the "automated HOT / COLD WIRE GTAW" clad weld quality issues will in reality come from five areas which are easy to control;

[1] Poor weld procedure practices and data taken from unsuitable PQR data. The clad bore procedures are many times qualified on pipe coupons which have little in common with the actual valve bore welds.

[2] Failure of weld management and engineers to provide complete clad weld and manufacturing instructions for the shop floor personnel.

[3] The use of an out dated automated automated / manual GTAW clad weld process. If they are not using TIP TIG they are using an inferior weld / clad process.

[4] The automated equipment that rotates either the torch or parts, is frequently inconsistent, poorly calibrated and highly sensitive to minute weld process, consumable and equipment changes. Remember TIG with the HOT - COLD wire process is highly arc length sensitive.

[5] The management fails to establish uniform best weld practices and fails to provide their engineers, technicians, supervisors and weld shop personnel with the effective process control - best practice training.


2009: MANY IN THE SUB SEA FAB INDUSTRY NEED A WELD PROCESS WAKE UP CALL.



Its now 2015. When any industry has the highest possible weld quality demands and that industry is not aware of a superior and easier to use manual / auto weld process than the traditional GTAW process, what does that say about the managers and engineers running the weld departments?

On the right we have a typical automated Inconel or stainless clad bore weld. The reality with deep sea valve weld applications is they will usually have an automated and manual clad weld spec or standard that is actually less forgiving than the traditional ASME standards applied to welds made in a Nuclear plant.

When any plant has to work with demanding weld requirements, you woul think that its a logical responsibility of the prime weld decision makers to ensure the best possible weld processes

With the TIP TIG Automated clad and the Manual weld process, a weld department will have a process in which;

[] The TIP TIG process is the same for both the required automated and manual welds, (does not require Hot - Cold Wire).

[] With most welds made with no more than four weld settings, and a process wasier to use, the TIP TIG process will simplify both the welder qualification and the weld procedures..

[] With TIP TIG, the automated weld process arc length sensitivity is dramatically reduced and weld deposition rates are dramatically increased.

[] With this traditional Hot TIG Wire clad weld, after the welds are complete, the large sub sea valves will be delivered to the machine shop for the complex and time consuming set up required to machine the clad weld surface. While machining, the machine shop will typically find unaceptable weld pores, oxide inclusions and the occasional lack of weld fusion defects. These are the same defects found in most multipass conventional manual TIG and automated Cold and Hot wire TIG applications.

[] In contrast, with the The TIP TIG automated process, the weld puddle dynamics are dramatically changed. The TIP TIG weld pool agitation, (slows weld solidification). TIP TIG also enables increased weld current that comes from the higher wire feed potential. The improved weld wetting, the increased weld energy and the lower weld heat that comes from the faster weld speeds, enables much higher multipass clad weld quality and higher clad weld speeds The improvements in weld quality and faster weld speeds will provide dramatic cost benefits for both the weld and machine shops.

[] On these valve bore clad welds TIP TIG should readily allow a 50 - 70% increase in weld deposition rates which apart from the obvious labor saving costs also reduces the weld gas costs by approx.. 50%.

[] When ever you deal with oil company applications you typically will find hundreds of weld procedures, when you set up TIP TIG you likely will not require more than three sets of weld parameters.


[] One thing to always keep in mind is the TIP TIG manual process even when utilized for repair welds will consistently deliver better quaity than any automated Hot - Cold Wire GTA weld.

 

 

Manual or automated the TIP TIG weld quality
is always the highest possible..


TiP TiG provides unique auto pipe weld equip.




TIP TIG APPLICATION:

2205 DUPLEX INDUSTRIAL HEATING BOILERS.
Thin gage. 0.035 - 0.045 (1 - 1.2 mm).

TIP TIG WELD QUALITY: TIP TIG will provide your organization with the manual and automated capability to attain weld / clad quality levels way beyond the conventional TIG - PLASMA - PULSED MIG - MIG SPRAY - MIG STT / RMD / CMT and Flux Cored.

A problem most people have with these full penetration thin gage boiler materials and their requirements for defect free welds, is the duplex weld is sluggish and weld wetting is poor which effects the weld fusion and weld travel rates.  The customer typically used a maximum welding travel speed with a conventional automatic cold wire TIG set at 15-17 inch / min).

The first TIP TIG welding parameters and speeds we achieved with an 0.035 (1mm) 2205 Duplex cold wire are as follows:

Welding Current :   190Amps
Welding Voltage:    12.5Volts
Travel Speed:-         Double at 35 inch/min. The UK TIP TIG rep Darren Mathieson, reported. The time he had at the facility was limited and that this application could readily exceed 40 inches 100cm/min. The customer stated the defect free weld we achieved were welds with a superior bead appearance, less weld distortion, and the process was much more stable and consistent.

 

 


TIP TIG APPLICATION:
AUTOMATED WELDS VACUUM BOILER COMPONENTS.


Material: Carbon steel.
TIP TIG Welding current: 190A
Material thickness: 0.050 (1.5mm)
TIP TIG Welding speed: 18 inch/min (450mm/min)
TIP TIG Welding wire 0.035 (1mm).


This full penetration vacuum application required defect free welds and the regular automated TIG system was slow and had weld instability issues which affected the weld quality. TIP TIG eliminated weld issues and established quality and productivity levels.

 




TIP TIG APPLICATION:
HYDRAULIC PARTS.
High pressure hydraulic components.
Automated Bushing welds on 5 mm, carbon steel.

TIP TIG provided consistent 100 % defect free welds with an 0.035 (1mm) wire, welded with 260 amps. The bushing weld cycle time was 15 seconds. With pulsed MIG
you would have had lack of weld fusion concerns. There is no other process that will repeat the weld quality attained on this automated weld project and the weld equipment costs were under $10.000.


 


TIP TIG APPLICATION:
STAINLESS, TANK WELDS.

Tank Wall Thickness 5/8. 15mm. Vee Groove
TiP TiG automated weld speed: 16 inch/min 400 mm/min
Wire specification: EN 12072 W19123L Si.

What you are getting here with TiP TiG is defect free weld quality thats superior to conventional TIG and pulsed MIG. The Vee groove weld speeds were approx. 16 inch/min, you could easily achieve this speed with pulsed MIG or flux cored, the question would be how confident would you be that the pulsed MIG and gas shielded flux cored weld radiographs or UT will not find those costly to repair weld defects.. By the way what a pleasant weld shop, the welders enjoy working with a process in which spatter is none existant and fumes are not visable.

 




TIP TIG APPLICATION.

ROBOT BRAZED WELD
WELD REQUIRED SUPERIOR
COSMETIC WELD SURFACE:

This Cyberweld TIP TIG success was an ABB robot brazing application on the Jaguar X150 cars. Origionally a robot MIG braze system with Vision Guidance had been installed at the plant to perform the welds on the car roof joints. The quality of the finish of the MIG weld was considered critical, and the robot supplier (as usual) had not been up to the task to achieve the MIG braze quality required by Jaguar engineers.

By the way it's obvious looking at the
cumbersome robot selected that the Jag engineers had made some very poor equipment choices for this application, (engineers that are paid to know better). The responsible engineers and technicians worked on the MIG braze problems for a number of months without success. It took a few hours with this poorly suited robot and the TIP TIG process to provide the braze weld quality required by Ford.

 

ROBOT GTAW HOT - COLD WIRE VERSUS TIP TIG..

Process experienced manufacturing managers, engineers and robot integrators, would with process expertise shy away from a robot application that requires complex welds with the regular TIG, Hot Wire, or Cold Wire TIG process. The reasons for the apprehension would be that in the past these companies may have experienced on their robot GTAW weld applications, that the robot controlled HOT WIRE TIG process, (wire preheated approx. 60 - 100 amps) can be extremely sensitive to arc length variations and many other weld variables. With too many robot GTAW applications, robot Down Time will often compete with robot Uptime.

Usually with robots and conventional GTAW, a tight limit and balance is required between the TIG wire feed rates, the weld travel rates, the weld arc lengths, the weld current and always a concern, the exact GTA wire placement in the narrow plasma TIG arc and small fast solidifying weld pool.

The conventional automated Hot Wire TIG the process sensitivity is further enhanced with the low weld deposition that influences the current utilized. On many robot GTAW applications, due to the narrow, low energy plasma generated, a small diameter wire is typical and 0.030 - 0.035 are often the norm. Typical HOT - Cold wire feed rates are in 1 to 3 m/min range. The low Hot - Cold wire feed rates will require slow robot weld speeds.

NO PRODUCTION - TOO MUCH WELD HEAT AND COMPLEXITY ADDED BY THE ROBOT, WHY BOTHER?

Its an ironic point that few managers or engineers seem to be aware of. With the purchase of that costly robot regular Hot / Cold Wire TIG cell, the typical robot weld deposition rates attained with these processes are usually not much more than that enabled by a single MANUAL TIG welder who would of course be using a much larger TIG weld wire diameter such as an 0.062 or 3/32 wire and also would not have the typical robot down time issues.

Note: Cold Wire GTAW also has weld wire fed into the TIG arc plasm, without the filler wire being preheated. With the Cold Wire process and robot welds, the process sensitivity is increased and the weld concerns just get worse.


 

THE GTAW SOLUTION FOR ROBOTS HAS FOR MORE THAN A DECADE BEEN TIP TIG.

Around 2010 or 2011, I approached Wolf Robotics (used to be ABB robots Arc Weld Division for USA) with the TIP TIG process. Like most robot companies the salesman are the key players and as with most weld salesman, there is usually a lack of weld process expertise. Its therefore no surprise that with some of the salesman that the response to TIP TIG was that they had minimal interest in a weld process that was not considered conventional, or was not sold by Miller - ESAB or Lincoln. As with many key weld personnel the fear of change was part of their daily routine..

Someone in the ABB USA marketing or engineering department, must have finally woke up a couple of years later to recognize and embrace the extraordinary robot GTAW weld quality / productivity / metallurgical and cost benefits attainable with the TIP TIG process. In 2015, ABB now offers the weld industry extraordinary weld opportunities with the ABB Robot / TIP TIG weld cells.

Note: As you can tell, I have little patience for so called qualified weld engineers, managers, supervisors, technicians or sales reps who are apathetic or slow to embrace new weld technology, especially when that technology can enhance their companies's capability, reputation, growth and also provide a unique opportunity for increased profits. I get even more frustrated with these individuals when they don't have to find the new weld technology and its presented to them on a silver platter. Think about the weld application and process comparision data available at this web site.

By the way I am qualified to talk about weld sales people, as in my Corporate role over four decades as Training, Marketing and Product mgr. with Air Gas, AGA, Praxair, and Liquid Carbonic, I personally trained over 2000 weld sales reps on weld process controls. I also can comment on ABB, as I used to be the North American corporate Robot Weld Trouble Sh
ooter at ABB Headquarters. Michigan, and later the Robot Weld mgr. at ABB Robots Colorado. With arc welding applications the choice of robots is of course important, and in 2015 as I did twenty years previous, I believe that the Swedish pragmatic - practical approach to engineering and their logical weld software, that the ABB Swedish built robots are still my first choice for "arc welding" robots. I have always had great respect for the ABB technical people who build and integrate those robots. However if you integrate robots and don't bother to become a weld process control expert, perhaps you are in the wrong profession and would be better suited to working for Starbucks.

 

 

2015: Great automated weld combo. ABB robot & TIP TIG.

 

As an automated process, TIP TIG in contrast to the traditional automated Hot & Cold wire GTAW process is a much more ROBUST weld process that with the enhanced GTA weld dynamics is simply less sensitive to the arc length variations that can occur with many GTAW welds.

ARC LENGTH INFLUNCED BY THE PARTS, WELDS, ROBOT PROGRAMMING & TUNGSTEN WEAR.

Where conventional GTAW and Hot - Cold Wire GTAW can created many variables that were a concern, the TIP TIP process will reduce or eliminate these variables. Of special value with robot TIP TIG welds is the fact that TIP TIG enables higher weld / clad quality than GTAW, and also much higher GTAW weld deposition rates. The increase in weld deposition allows an increase in the TIG current (more intense wider TIG plasma) and a dramatic increase in robot GTAW weld travel speeds.

The increased robot weld speeds from TIP TIG not only dramatically increases the GTAW weld production, the faster TIPTIG weld speeds also enable lower weld / part joules for a dramatic decrease in the part weld distortion potential.

The robot / TIP TIG bottom line. TIP TIG is an easy weld / clad process to use with most weld automation and especially when used with robots. The ABB - TIP TIG combination will provide consistent, extraordinary weld quality at higher weld production rates than the normal GTAW or Hot Wire process. By the way this is a process you only consider when the MIG process does not meet your weld quality requirements or meet your weld / part metallurgical needs.


TIP TIG and COMMON AUTOMATED SEAM WELDS.


Optimum weld quality & high weld speeds
TIP TIG is the best process for traditional tank / pipe SEAM welds.




TIP TIG Seam Weld data. Stainless thin gage 0.050 (1.5mm), 100 - 300% faster..

Weld requirements. Single Pass, full fusion, defect free.

TIP TIG Weld Amps 180A. Seam Weld Speed.. 30 inch/min.

If you use regular TIG - Hot or Cold Wire TIG for seam welds, please note,
that a change to TIP TIG will likely increase your seam weld production in the range of 100 - 300%
.. Hey it's only money and some manager or engineer might make a name for themselves.

 

 



 

While many weld companies would be happy with a 10 - 15% increase in TIG weld productivity, with TIP TIG we can show you better weld quality with a conservative productivity increase typically in the range of 100 to 400%.

 




Note the TIP TIG weld cleanliness, the extremely
small HAZ, no weld spatter or visable weld fumes.







IN CONTRAST TO REGULAR TIG, THE TIP TIG PROCESS IS COST EFFECTIVE FOR BOTH SMALL OR LARGE WELD APPLICATIONS.

KIS - KIS - KIS.. It's simple when only one weld process is required.........

AT MANY FACILITIES THAT DO CODE QUALITY STEEL WELDS OR ANY ALLOY WELDS, YOU WILL FIND THE USE OF MULTI-PROCESSES SUCH AS MIG - PULSED MIG - FCAW - TIG OR SMAW, NONE OF WHICH CAN PRODUCE THE WELD QUALITY POSSIBLE WITH TIP TIG..

When they are not asking a salesman for weld advice, weld shops usually will have many questions ON THE WELD PROCESS:

[] Which process should we use
for the pipe root?

[] Which process is best for the pipe fill passes?

[] Which process for those vert up / over head plate welds?

[] Which process will provide the best weld quality, lowest weld rework and best side wall fusion?

[] Which process enables best control of ferrite levels?

[] Which process produces the least distortion?

[] Which process provides the best metallurgical properties?

[] Which process is best for sluggish alloys?

[] Which process is best for the weld repairs?

[] Which process provides the cleanest welds?

[] Which process will enable the least weld pre-post heat?

[] Which process can use the smallest vee or J prep?

[] Which process provides the lowest weld dilution for cladd welds?


IT'S A BASIC FACT THAT CAN BE PROVEN WITH A QUICK TIP TIG DEMO ON ANY PARTS A COMPANY WOULD WANT TO SUBMIT. IF YOUR COMPANY HAS TO PRODUCE ALL POSITION CODE, OR HIGH QUALITY ALLOY WELDS, AND WANTS TO CONSISTENTLY PRODUCE OPTIMUM WELD - CLADD RESULTS WITHOUT WELD REWORK OR LIABILITY CONCERNS, CONSISDER TIP TIG.

 

 

 


WELDING STAINLESS, DUPLEX, INVAR OR ANY ALLOYS PLATES, TANKS
OR LARGE VESSELS THAT REQUIRE ROOT GAS PROTECTION?



TWO SIDED TIP TIG:

NO BACK PURGE,
NO CERAMIC BACKING,
NO GRINDING,
NO GOUGING,
NO ROOT REPAIRS
..

 


The two side TIP TIG open root technique is a a great cost saving solution for many open root applications.

 

 

 


A PICTURE IS WORTH A THOUSAND WORDS. TAKE A LOOK AT THIS TIP TIG, SINGLE PASS 1/4 (6mm) HORIZONTAL FILLET WELD.


TIP TIG MANUAL FILLET WELD. ALLOY 400.
Examine the weld energy, the weld consistency, examine the very small HAZ, the "untouched" unusual weld cleanliness and weld continuity.



 


 

FOR THOSE LOOKING AT "PULSED MIG FOR WELDS WITH NDT REQUIREMENTS.

ON MANY PULSED MIG (concentrated arc plasma) ALL POSITION WELDS ON STEELS > 5mm, DUE TO REVERSE POLARITY, ANTICIPATE HIGH WELD HEAT DRIVEN INTO THE PARTS HAZ.

[] WITH THE LOW PULSED BACK GROUND CURRENT FOR 50% OF THE ARC CYCLE IS TYPICALLY LESS THAN 100 AMPS INFLUENCES THE WELD ENERGY AND WELD FUSION.

[] WITHOUT OPTIMUM PROCESS PARAMETER CONTROL, EXPECT WELD SPATTER AND WELD TRANSFER INCONSISTENCY.

[] WITH THE REACTIVE PULSED MIG GAS MIXES EXPECT WELD POROSITY & OXIDE INCLUSIONS.

[] WITH THE TYPICAL PULSED MIG DEPOSITION RATES THAT IN CONTRAST TO SMAW AND TIG CAN READILY BE BE 6 TO 10 TIMES GREATER, THE PULSED MIG MANUAL WELD SPEEDS ARE MUCH FASTER AND IN MANY INSTANCES ARE TO QUICK TO ENABLE THE REQUIRED WELD FUSION.

AS DISCUSSED IN MY BOOKS AND PULSED MIG SECTIONS ARE A FEW OF THE REASON HAS POOR SUITABILTY TO ATTAIN DEFECT FREE, "MANUAL" ALL POSITION, CODE QUALITY WELDS.


In the last three decades, while the costs of MIG equipment was being driven downwards, the major global weld equipment manufactures found electronics, and then found out what bells and whistles could be added to their MIG equipment.

MAKE IT MORE SOPHISTICATED AND JACK UP THE PRICE.

2015.. I have evaluated Pulsed MIG equipment since the 1980s and the weld reality is the real world practical "steels and alloy steels" weld benefits attained from the pulsed electronics are often only in the mind of the pulsed MIG equipment manufactures and the weld equipment salesman.


2015: After personally evaluating pulsed MIG equipment for more than 25 years, from my perspective I believe that the REP Pulsed MIG process is not capable of providing optimum, "consistent", all position weld fusion especially on applications over > 6 mm. The pulsed MIG weld issues become more of a concern if the steels or alloys welded are considered "sluggish".


[] The fluctuating pulsed MIG peak to back ground parameters provide an inconsistent arc plasma. And with a process that provides a back ground current (50% of arc time) of less than 100 amps this often provides less weld energy than is sometimes desired for the weld depostion provided..

[] 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 the EN - TIP TIG welds should always be cleaner.

[] With the Pulsed MIG process you will have "wire stick out (WSO) changes" during the weld. The common WSO variations can typically provide 10 to 25% changes to the pulsed MIG 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 weld tie-ins data.


Feb. 19 2010:
E-Mail.
Subject: MILLER PIPE PRO AND PIPE WELDS:

Ed. Reference our recent experience with Miller Pipe Pro MIG for pipe root / fill passes.

PIPE ROOT WELDS & RMD: 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 & PULSED MIG: Mechanical testing of the pipe fill passes was then carried out for the same pipes with the Miller Pulsed MIG mode 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 and it was noteable that the TIG side bend tests had zero defects. For the fill passes we used the pulsed MIG process. With this process  we 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 the welders first time pass 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:


Email:

Ed, the Pulsed MIG mode is a sucessful pipe weld process when used on automated pipe weld systems, so why is it less sucessful with manual pipe welds?

Ed's Answer. The automated pipe weld systems provide what no manual pipe welder can provide. They provide regulated weld speeds, wire stick out control and regulated weld weaves. With the weld weaves, you may also be able to produce increased voltage energy spikes at the weave ends, this improves the side wall and weld tie in fusion.


Ed developed the world's largest web program on MIG - Flux Cored Best Weld Practices and Weld Process Controls, its called www.weldreality.com.

 

 


 



WELDING STEELS AND ALLOY STEELS.
TIP TIG IN CONTRAST TO PULSED MIG:


Process Typ Volts Typ Opt Weld Transfer
and AMP RANGE
Control of
Arc Starts
Arc Stops
Reactive
Gas or special mixes?
Wire
Stick out
influence
All position
root fill pass
capability
Heat sensitive alloys
REP PULSED
MIG
23
28
100 - 350
No

Required. Influence oxide reaction.

Negative
Not Capable
High heat
EN
TIP TIG
12
16
100 - 450
Yes
Not required.

Least oxidation.
N/A
First Choice
Lowest heat

 


 

 

IN CONTRAST TO REGULAR TIG, THE TIP TIG PROCESS WHEN WELDING LARGE DIAMETER OR THICK WALL PIPE, WILL TYPICALLY DELIVER ON AVERAGE 200 TO 350% MORE WELD FOR THE PIPE FILL PASSES. ALSO THANKS TO THE FASTER TIP TIG WELD TRAVEL RATES, THE ELECTRODE NEGATIVE POLARITY WELD HEAT INPUT WILL BE MUCH LOWER THAN ANY OTHER ARC WELDING PROCESS.


 



STEELS & ALLOY STEEL WELDS.

MORE DIFFERENCES BETWEEN TIP TIG
AND THE PULSED MIG & FLUX CORED PROCESS:

[] TIP TIG in contrast to the reverse polarity (RP) pulsed MIG and the Gas Shielded Flux Cored weld process, enables much lower weld volts which when combined with the TIP TIG EN polarity and the moderate TIP TIG weld speeds can result in welds with the lowest possible weld Joules. The low TIP TIG weld heat enables extensive weld - clad - part mechanical and corrosion benefits along with lower weld distortion.

[] TIP TIG in contrast to pulsed MIG and flux cored enables the widest welding amp range with lower weld voltage. Also TIP TIG enables any ratio of weld wire to current, whereas both the pulsed MIG and flux cored wire feed rate set will determine the weld current required. The TIP TIG benefits can dramatically increase the all position weld fusion capability, the weld application thickness range, and also reduce the concerns with SLUGGISH alloys..


When a process is so user friendly, you can have
two welders working within a few inches from each other,
without concern for heat, spatter or fumes


[] TIP TIG in contrast to pulsed MIG and flux cored enables amp ramp up / down data that provides superior quality on any Weld Starts / Stops and Tie-ins.

[] TIP TIG in contrast to pulsed MIG and flux cored is not influenced by the common wire stick out changes that occur and can dramatically change the MIG and FCA weld current..

[] TIP TIG in contrast to pulsed MIG and flux cored should always consistently enable both superior weld fusion and as TIP TIG welds provide more weld energy with an inert gas, these welds will have less oxide reactions and therefore produce less internal pores (porosity) and inclusion weld defects.

[] TIP TIG in contrast to pulsed MIG & flux cored, will produce NO weld Spatter.

[] TIP TIG in contrast to pulsed MIG and flux cored can reduce pre-heat / inter pass requirements or concerns .

[] TIP TIG when used for Clad or Hard Facing welds can in contrast to Pulsed MIG and FCA, produce less weld dilution (less passes required) and welds with less sensitivity to cracks.





Note the one hand & the shiny, untouched fill pass surface.
The easy to learn TIP TIG pipe welds should require no grinding,
produce no weld spatter and lowest weld fumes .

 

[] TIP TIG in contrast to pulsed MIG and FCA uses straight argon, and has the lowest possible weld oxidation potential producing cleaner welds on any parts. With the TIP TIG low weld joules and the inert gas expect with TIP TIG the lowest possible weld fumes, and welds that 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, MIG STT, and MIG short circuit RMD. Also the easier to use TIP TIG process will always provide superior all position fill pass weld quality and the smallest possible HAZ.


 

 


Thick or Thin... On these 409 thin gage parts, the Pulsed MIG
welds could simply never attain the weld quality of TIP TIG.

Left: Untouched 100% penetration, TIP TIG tube weld made at 30 inch/min. Right: The customers Pulsed MIG weld 100% penetration weld. Apart from the obvious quality differences, look at the weld HAZ heat affect.





Code welds and E71T-1
Gas Shielded Flux Cored Wires.

No matter what the consumable manufactures claim, you know with flux
cored wires there will be NO optimum weld quality guarantees.




WELD SHOP GRINDING - CLEANING & WASTE:



Its' a shame in those weld shops that weld stainless, inconel 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 if you need a GRINDER, a WIRE BRUSH
or an EXHAUST unit... WHY?




WELD SMALL SIZE < 4 mm FILLET WELDS AND LONG FILLET WELD LENGTHS:
Providing controlled long length, consistent optimum quality, small 2.5 - 4 mm fillet welds has for decades been a challenge for the global weld industry. MIG frequently deposits too much weld and does not have the focused energy necessary for the welds which typically will be over size. Also the weld heat from the REP MIG process often provides weld distortion issues. Regular TIG will have too many weld start / stops and the slow TIG process may also provide weld heat concerns.

It's important to emphasize that with the TIP TIG process that in contrast to regular TIG, the prime weld benefit is not just about greater TIG weld deposition rates, the lower weld heat input TIP TIG welds should in the majority of weld applications produce welds with the lowest oxidation, the lowest distortion, the least weld pores, superior side wall fusion, much less arc start / stops, and the smallest heat affected zones. Visit the home section to view a great video on TIP TIG sheet metal welding,

 



TIP TIG best process for pipe
weld roots and fill passes.






TIP TIG APPLICATION:

HALF PIPE STAINLESS
SNAKE WELDS
..

As the TIP TIG welder no longer has to feed a weld wire with one hand or worry about a leg cramp with that foot control, the TIP TIG welder can focus soley on the weld and use one hand to stabilize his body or put two hands on the torch for extra torch control. Remember with TIP TIG, the constant fed wire is always fed into the arc sweet spot.

PULSED MIG FAILURE: With the the half pipe snake weld application indicated in the photos, the weld shop did not like the inconsistent weld quality, the weld distortion, the weld fumes and weld spatter cleaning required with the Pulsed MIG process, so they turned to TIP TIG..

These stainless 316L tanks and similar tanks are typically used in chemical, pharmacy and food industry. This vessel was for BASF Germany. BASF demands the highest possible weld quality. If this project manually welded with the traditional TIG process, TIG and a 3/32 wire would have a weld deposition rate average of approx. 0.3 lb/hr with weld speeds typically in the range of 2 - 3 inch/min with more start /stops than you could count. In contrast, the manual TIP TIG weld deposition rates on this application enabled manual weld speeds for the 3/16 fillets of 12 - 15 inch/min. These manual TIP TIG weld speeds and the small TIP TIG HAZ ensured minimum distortion. BASF. QA and weld personnel were amazed at the defect free weld quality. Of course with no weld spatter and weld smoke safety issues, and at the weld completion the weld surface cleaning was dramatically reduced.

[1] MORE TIP TIG WELD BENEFITS:
WELDER COMFORT AND WELD QUALITY:

Most weld personnel that have a good attitude and can embrace change will need a few hours to get used to the TIP TIG torch, the weld requirements and TIP TIG techniques. With the light weight TIP TIG torch, welders can use one or two hands on the torch and not having a foot control for most applications is a big plus for many. It's important for management to remember that when welding pipes, aircraft parts, turbine vanes or welds on a nuclear submarine, the more comfortable the welder and the less skills required, the greater the potential for optimum, consistent weld quality and productivity.

[2] TIP TIG WELD BENEFITS:
ALWAYS SUPERIOR MANUAL & AUTOMATED WELD QUALITY:

In the last decade, the two growth weld processes for all position pipe welds has been pulsed MIG and Flux Cored. Both of these processes when used in manual pipe applications will irrespective of the manual welders skills produce common weld defects as discussed in this section and in the Pulsed MIG / Flux Cored sections in my weldreality.com site. The Pulsed MIG and flux cored weld processes are not suited for open root welds and the defects that will be derived from both these processes on code applications will typically require additional NDT costs and costly weld repairs. In contrast a ten minute demo with the TIP TIG process would reveal it should always deliver manual or mechanized weld quality thats superior to traditional TIG - Pulsed MIG - Fronius CMT - Miller RMD - Lincoln STT - MIG Spray - Short Circuit - Flux Cored.

[3] TIP TIG WELD BENEFITS:
MUCH LOWER WELD LABOR COSTS:

If you are involved with weld costs, be aware that every time you have two or three welders using the conventional TIG or SMAW weld processes, one welder using the TIP TIG process will typically produce similar production and always produce superior weld quality.

In this time of difficulty in finding skilled welders, weld shops should be aware of the value of process that requires less weld personnel, is easier to teach and always provides the highest possible all position weld quality.


[4] TIP TIG WELD BENEFITS:
LOWEST WELD FUMES:

OSHA 2010 has new strict safety regulations for welders working with high chrome alloys, (chrome fumes - particles concerns). On most stainless weld applications, irrespective of the alloys used the TIP TIG process will typic ally not require exhaust equipment. Thanks to the increased TIP TIG weld speeds and electrode negative, no other weld process including regular TIG will provide less weld fumes than TIP TIG.
Note the lack of TIP TIG weld fumes " inside" this stainless vessel...



[5] TIP TIG WELD BENEFITS:
FEW SIMPLE WELD PROCEDURES REQUIRED:

That new nuclear or coal fired power plant, or the new oil rig if welded by the TIP TIG process could be built with a manual and automated weld quality and productivity never before attained. No matter how difficult the welds or how complex the welding alloys are, typically three to four common TIP TIG wire feed - amp weld settings would apply for any weld application, any weld position and any steel or alloy.


 

TIP TIG APPLICATION:
2010. CROTIA SHIP YARD.
TIP TIG WELDS LEAN DUPLEX TANKS


WHEN YOU HAVE EXPERTISE WITH DUPLEX - NICKEL AND STAINLESS ALLOYS, YOU QUICKLY REALIZE THE WELD BENEFITS OF TIP TIG.

24 TIP TIG units were used to weld these Lean Duplex Tanks 1/4 - 3/8.
(6-9mm) The ships contaIners were 12 - 17 meters wide by 20 meters in height. The ship yard attained a weld quality and production never before attained with regular TIG on duplex pipe, plate and vessels.

 

 

 

 

TIP TIG far superior to the HOT - Cold Wire TIG process for weld automation.



 

 

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


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


 

 

 

 

With manual or weld automation, it would take less than a 30 minutes to demonstrate that the TIP TIG process will produce superior all position weld / clad quality than that possible from regular TIG, Hot Wire TIG, Cold Wire TIG, Pulsed MIG or the Short Circuit process.

CLADDING, HIGHEST QUALITY, NO SPATTER,- LOWEST PART HEAT:

It took me less than 15 minutes to establish the optimum data required for this TiP TiG no spatter, defect free, ID bore automated clad weld. By the way pulsed MIG provided excess heat issues that were resolved with TIP TIG Check video.

 

 



TIG Welding Brochure



LOOKING FOR SKILLED PIPE WELDERS? WITH TIP TIG, PIPE WELDER SKILLS AND TYPICAL TRAINING TIME REQUIRED ARE DRAMATICALLY REDUCED:

Left: Traditional TIG requiring two hands, a foot control, high skills. The process traditional manual TIG process will deliver inconsistent wire feed, and wire placement in welds, and also deliver many start / stops. The slow weld speeds have to deliver high weld heat.




WHEN YOU SIMPLIFY A WELD PROCESS, WELD MANAGEMENT NEEDS TO TAKE NOTE:

In contrast to TIG, with TIP TIG the welder uses one hand does not require a foot control and is therefore more relaxed. TIP TIG delivers higher weld energy, yet lower wed part heat. The wire is fed at a consistent wire feed rate and always directed into the weld pool sweet spot.


 

 

If you use or are considering regular TIG, Pulsed MIG or Flux Cored on high quality code weld applications like the welders below, you will likely end up paying for costly weld rework. You can avoid weld rework with the TIP TIG process.

 

 

You know when you are in a weld shop
thats using outdated weld methods.


 

 


TIP TIG Application:
Inconel Screw Weld:

Weld Wire: Inconel-625.
Wire Size 0.045 (1.2mm).
Shield Gas, Argon.


On this application, the TIP TIG amp range was 300 - 380A. Weld deposition rate for this application was 400% greater than possible with regular TIG.

Remarks: For those of you that use costly helium - argon, or argon - hydrogen gas mixes, these mixes are rarely required with TIP TIG as
this process enables an agitated weld pool with higher current that results in a slower solidifying weld pool that provide more weld energy than traditional TIG.

With TIP TIG we have a process that for the first time with a manual/automated process enables the highest first time weld quality. Thanks to the TIP TIG high weld energy and puddle agitation, the welds had no fusion concerns and the welds were 100% free of pores and defects. Note how the one hand Inconel welds were made with ease.

 



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





Is your company stuck in a 1960s weld shop Time Warp?
and considering the SMAW (STICK) process for your code or alloy welds?

Every weld shop knows the weld issues generated with the stick weld process. And every weld supevisor knows that the only way to attain optimum, first time weld quality with the stick process is to provide the "welder with a grinder".

If all position, code weld quality, optimum weld cleanliness, weld continuity, weld uniformity with the lowest weld heat input are factors that will benefit your applicatio, you may want to give consideration to the TIP TIG process.






QA WELD MANAGEMENT PLEASE NOTE:

THE MANUAL OR AUTOMATED TIP TIG PROCESS SHOULD REDUCE THE REQUIRED WELD PROCEDURES. TIP TIG WILL SIMPLIFY THOSE WELD PROCEDURES, THE WELD QUALIFICATION AND ALSO CREATE OPTIMUM WELDER CONFORMANCE.

For the typical weld shop, think about the variety of the weld equipment and weld consumable options. Welders will daily use regular TIG - SMAW - MIG - STT - RMD - Flux Cored and Metal Cored and too often many welders who lack process control expertise will "play around" with their weld controls.

Considering Pulsed MIG for your weld procedures? Be aware that those complex Pulsed MIG weld procedures should change when that different Pulsed MIG power source is used, or new, ever evolving Pulsed MIG power source are introduced to the weld shop bringing changes to the weld essential variables.

KIS - KIS - KIS: As someone who has spent 40 plus ears simplifying and optimizing MIG and flux cored weld quality and productivity and has developed hundreds of weld procedures in 12 countries, I know the importance of keeping things simple in the weld shop.

When weld shops have to start thinking about MIG Short Circuit - MIG Spray - MIG Globular - MIG Pulsed - MIG STT - MIG RMD - MIG CMT - Gas Shielded Flux Cored and the traditional TIG and SMAW processes and numerous weld consumables, you know weld issues will always be around the corner and life in the weld shop is not going to be simple. In contrast, when using TIP TIG, you will have one weld gas argon and two or four simple wire feed and amp weld settings and that's all any weld shop will require to produce cost effective, defect free manual or automated welds on any alloy, any weld position and any application.

 



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


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




TIP TIG A WELD SOLUTION TO STAINLESS EXHAUSTS, MINOR MIG SPATTER CONCERNS.

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




TIP TIG SMALL MANIFOLD APPLICATION:
TESCOM Material: 1.4404 Tube:
Tube Diameter 20 mm.
Wall thickness 5.5mm
TiP TIG Filler material: 1.4430.



The above manual TIP TIG welds made on a rotary positioner required 3 passes for the almost 1/4 (5.5 mm) weld vee prep. In contrast to traditional TIG, the manual TIP TIG welds were more uniform and for those that care about weld costs, the TIP TIG weld time reduction was 150%. Note the manual weld continuity and the small weld heat affected zone from the 3 untouched TIP TIG weld passes.




TIP TIG Application:

Hastelloy C22 Screw.
Weld Wire: Hastelloy C22
Weld Position: 2G.

Remarks: Highest quality, lowest oxidation,
great continuity, full penetration defect free welds.


Note: The single pass size with this TIP TIG, Hastelloy C22 fillet weld continuity. Also take note of the untouched clean welds with the lack of evident weld oxidation. Take note also of the small weld HAZ. The TIP TIG manual weld speed with the welds was 300 - 400% faster than possible with traditional TIG. It's not possible to duplicate this TIP TIG weld quality with traditional manual TIG, Flux Cored or the Pulsed MIG process.

 

 


TIG 1/4 (6mm) STAINLESS FILLET.


FIRST TIME USER WITH THE TIP TIG WELDING STAINLESS:

WELDING 1/4 (6 mm) OUTSIDE CORNER WELD. NOTE THE TIP TIG PROCESS IS WELDING FASTER THAN THE REGULAR TIG PROCESS WELDING THE 1/8 (3mm) FILLET IN THE ABOVE LEFT VIDEO.

On most stainless welds, TIP TIG willl produce superior weld quality than the regular TIG process. If you are thinking about pulsed MIG, with TIP TIG again you have much superior weld quality, the lowest possible weld heat input, the lowest fumes and of course, welds without spatter.

 

Note: If a regular TIG welder was doing this 1/4 (6mm) fillet weld,
they would typically do 2 weld passes and use an aggresive weave.

 


TIP TIG provides extensive weld benefits for the Chemical, Oil, Ship Building, Aerospace, Beverage and Food Processing Equip industries.




two sideTanks, Pressure Vessels, Plate Fabricators. Duplex - Invar - Stainless - Inconels - All Corrosion and Wear and Heat Resistant Alloys.

Typical Flux Cored weld issues with tank and plate pressure vessels. For many stainless and duplex tank, plate or pipe welds, companies may consider the slow regular TIG, high weld heat input process or the faster flux cored process to weld their alloy applications.

The all position gas shielded flux cored process utilized for these weld will often be responsible for many weld issues including weld fume concerns, internal weld slag, weld porosity, lack of fusion and excess weld spatter.

Flux cored weld (FCAW) defects revealed by NDT will often require extensive back gouging, grinding and cleaning. Companies utilizing SMAW will increase their labor cost and have similar issues to the FCA welds. Manual pulsed MIG will produce much cleaner welds however the welds will depending on the alloy and part thickness produce lack of weld fusion concerns. With regular TIG it takes forever yet their will be just miniscule defects or heat / oxidation concerns. There is only one weld process that can get all position first time manual weld quality on these applications and that process is TIP TIG.

Note: In contrast to regular TIG the TIP TIG process is suited to any wall thickness.

With TIP TIG the welder can weld an open root plate, tank or vessel using the unique TIP TIG Two Sided Weld Technique. On a Two Sided open root vee groove welds, no back bars, no ceramic backing, no back gouging, minimum weld smoke, no spatter, no slag, no porosity, consistent weld fusion with the lowest weld distortion are now possible. The TIP TIG two sided root welds on your stainless or duplex applications will avoid the high gas costs associated with purging the open root tank and vessel welds. We will be glad to demo this technique at any of our open houses.

 


ONE WAY TO ELIMINATE A GOOD SIZE VESSEL
OR TANK ROOT GAS PURGE:


WITH TIP TIG, WELDERS CAN PERFORM TWO SIDED TIP TIG OPEN ROOT WELDS ELIMINATING TANK OR VESSEL GAS PURGING AND BACK GOUGING ON ALLOYS THAT REQUIRE ROOT BACK SIDE GAS PROTECTION.

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

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

 

 

TIP TIG. TWO SIDED ROOT WELDS. COULD BE PLATE, TANKS, VESSELS OR PIPE.


Any weld alloy that requires an open root and typically requires a purge to protect the root is an application in which you may want to consider TIP TIG.

The above TIP TIG demo is simply a piece of stainless plate with an open root. Imagine this root is part of a 30 foot diameter duplex or stainless tank, how would you approach that root protection?

 


 


WHY STRUGGLE WITH FLUX CORED OR PULSED MIG VERT UP OR OVERHEAD WELDS WHEN YOU CAN PRODUCE A MANUAL TIP TIG DUPLEX, STAINLESS OR ANY ALLOY UNTOUCHED FILLET WELD THAT HAS THE QUALITY OF THIS TIP TIG OVERHEAD WELD?

Untouched, TIP TIG single pass,
over head weld, 5/8 (15mm) Duplex:

 



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

 



ALL POSITION WELDS. TANKS & VESSELS "PLATE WELDS":

 

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

This single pass, vertical up TIP TIG duplex weld was made by a a first time user of the TIP TIG process. Note the untouched weld color and small weld HAZ.






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




Note the portability of the TIP TIG wire feeders.

 



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

 

 

[] TIG TIP welds with higher deposition rates than traditional TIG, so the TIP TIG weld gas costs will be dramatically reduced by 50 - 200 %.

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

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

[] TIP welds typically from 50 to 500% faster than all traditional manual TIG welds.

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

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

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

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

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

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

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

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

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

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

Over 25 years ago, in Thailand, I managed a project repairing failed (cracked) welds and plate on USA manufactured, Textron Sting Ray tanks. The tanks were sold to the Thai Army. Ed in middle photo. I wish at that time I had TIP TIG to do the weld repairs on the highly weld heat sensitive 287K tensile armor plate.




2015: Both the Aerospace and Defense industries have in my life time always been slow to accept new practical - cost effective weld technology. These industries weld many complex applications and alloys. If the management / engineers would take a few moments of weld process quality - cost evaluation, they would appreciate the TIP TIG process, especially when they desire to attain the highest possible weld quality with a process that also brings many weld cost benefits..

 

 




Take 15 minutes, attach the TIP TIG torch to a low cost
"automated weld carriage"
and you simply achieve the worlds best quality welds.


 

 


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

TIP TIG 409
16 GAGE SEAM WELDS.


TIP TIG 409
16 GAGE SEAM WELDS,

 

If you compared pulsed MIG with this 409 TIP TIG seam weld you would instantly note the superior weld quality from TIP TIG.

While the full penetration Pulsed MIG may have weld fume concerns, weld oxide formation, weld spatter, distortion, undercut and require manual cleaning or weld rework, in contrast the TIP TIG welds would not create these common weld production issues.

 

 

Customer wanted to see the quality and ease of use in a production capability for TIP TIG on this seam application. Set up was easy and required about 15 minutes. Simply attach the TIP TIG torch to a low cost auto carriage. The part welded is the first of 3 test pieces provided. At TIP TIG we don't need to "play around to attain optimum weld results. Within a few minutes we were continuously providing parts as shown on the left. With automated TIP TIG seam gage welds like this, you can anticipate the welds would be made between 25 and 35 inch/min. (typical 300 to 500% quicker than manual TIG and compatible with many MIG welds.

 





MANY WELDS DON'T HAVE THE "WELD QUALITY REQUIREMENTS" OR APPLICATION REQUIREMENTS TO JUSTIFY PURCHASE OF A TIP TIG UNIT. IF YOU ARE INTERESTED IN OPTIMIZING YOUR MIG OR FLUX CORED MANUAL OR ROBOT WELDS, INSTEAD SPEND $300 ON Ed's WELD PROCESS CONTROL TRAINING RESOURCES.



FROM SHIP YARDS, TO NUCLEAR PLANTS, FROM CONSTRUCTION EQUIP MFGs TO AUTOMOTIVE PLANTS. I HAVE OPTIMIZED "ROBOT / MANUAL WELDS" FOR HUNDREDS OF COMPANIES IN 13 COUNTRIES. A FEW OF MY ROBOT PROJECTS, THE FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS - CORVETTE FRAMES - HARLEY BIKE FRAMES - NEW VW BEETLE SEAT WELDS & THE ABB ROBOT WELD DATA NECESSARY FOR CATERPILLAR'S WORLD'S LARGEST TRUCK. If interested in Ed's manual and robot MIG and flux cored weld process control training programs, click here.






With weld cladding applications, there is a time for MIG and a time for the TiP TiG process. My Pulsed MIG patent for improving boiler water wall stainless / inconel clad welds came into effect as of April / 2010. The patent was issued to the world' largest cladding company, Welding Services, (Aquilex) . based in Atlanta USA.

My patent improves the traditional, global, Water Wall, clad weld quality attained. The pulsed MIG method, data and practices I developed, dramatically reduces any boiler wall distortion potential and also the clad weld stresses. This patent also reduced the amount of stainless or inconel clad material required per-square foot of clad surface by approx. >28%. It's hopeful if the management and engineers can take ownership, that this unique MIG process control approach will become the standard for WSI, a company who have been responsible for approx.. 75% of the boiler water wall clad welds made in North America and Europe. More on my MIG clad weld info is available here.

 



In Edmonton, Alberta Canada, the following complex
manifold was at first done with
Hot Wire TIG process.

 


 

TIP TIG increased this manifold application's automated Hot wire TIG feed rates by approx. 150%, and provided superior welds &
mechanicals with a dramatic reduction in weld distortion.

If you are considering a costly automated TIG weld application, don't weld at the speed of a snail, consider that TIP TIG will typically do the same
welds on average at 100 - 300% faster wire feed rates.

 







The World's Manual or Auto Best Pipe Weld Process
.


ONE weld process for root and fill.

 


During 2011, the largest Sub Sea Oil Company in China, the China National Offshore Oil Corporation. (CNOOC) was looking for a weld solution for one of its 20 mile sub sea pipe lines. The pipe was clad at it's ends with Inconel. The automated clad welds and the manual circumferential welds (bot had to be defect free) that followed were made on barges at sea.

CNOOC engineers had tried regular TIG and the most sophisticated global pulsed MIG equipment available for the inconel welds and the weld results due to weld heat build up were simply not satisfactory.

With a few hours of weld evalution I demonstrated to the Chinease engineers how the TIP TIG process could simplfy this application and still meet the on time weld production requirements for both their all position manual and automated welds. More info below.

 

 

 


DON'T TRY THIS WITH THE REGULAR TIG OR PULSED MIG PROCESS.


2 LAYER, UNTOUCHED, INCONEL, CLAD PIPE ID WELD: Note with this TIP TIG clad automation that no Arc Voltage Control was required. You will never attain a clad weld with this control, this quality and this low dilution with the regular TIG or Pulsed MIG process. With this application you attain the lowest weld dilution, lowest distortion, no spatter, no smoke, no weld cleaning and no weld rework. See finished weld below.

 



ONE PROCESS FOR ANY MANUAL OR AUTOMATED PIPE WELDS: With above application the TIP TIG process was use for the root - fill manual welds required for the all position circumferential pipe welds and also for the automated inconel pipe clad ID welds. One weld process for the manual and automated welds simplifies the weld equipment and consumables required and simplifies the weld procedures.

LOWEST POSSIBLE DEFECTS, BEST POSSIBLE PROPERTIES: TIP TIG will always produces superior weld quality than regular TIG and Pulsed MIG and always provide lower weld heat for optimum mechanical properties.

LOW LABOR COSTS: The TIP TIG manual and automated welds were 200 - 400% faster than the regular TIG process.


 


THIS SECTION SHOWS WHEN WELDING CODE QUALITY PIPE - PRESSURE VESSEL WELDS, WHY THE REGULAR MANUAL TIG, THE AUTOMATED HOT OR COLD WIRE TIG, FLUX CORED, PULSED MIG, RMD - STT MIG CANNOT COMPETE WITH TIP TIG.


 

TIP TIG PIPE WELD BENEFITS:
When manual welding pipe in any weld position, in contrast to the regular TIG process, the semi automatic or the automatic TIP TIG process offers many weld process control benefits.

[] TIP TIG enables controlled, consistent TIG wire feed rates which drives consistent, manual weld speeds and reduces the weld arc start / stops.

[] TIP TIG provides consistent manual wire to the optimum arc placement, this helps maintain uniform, consistent weld energy.

[] The higher energy welds from the TIP TIG Hot Wire current and the higher wire feed rates enable increased weld current will result in superior weld fusion and decreased porosity on any alloy.

[] The unique TIP TIG "agitated weld puddle" enables pore defects to exit the welds and dramatically increases side wall weld fusion and lowers weld stresses. This unique benefit also reduces the sensitivity to sluggish alloys.

[] In contrast to any weld processes you are using on your pipe welds, the high weld speed TIP TIG welds with EN polarity produce welds with the lowest weld heat and the smallest HAZ. The TIP TIG welds with always produce superior mechanicals and corrosion properties and the welds will produce the lowest oxidation leading to welds with the lowest pores - inclusions defects.

This TIP TIG close up reveals something that no manual TIG welder can ever achieve, consistently feed the weld wire into the TIG arc plasma sweet spot at a controlled wire feed rate.


 

 

IF REQUIRED TIP TIG ENABLES EXCELLENT
LOW COST WELD AUTOMATION..

TIP TIG PIPE WELD WITH A ROTARY POSITIONER. .


With or without that positioner, the semi-automatic TIP TIG process provides the best root - fill pass weld quality.

On any weld position the fill pass welds will have 100 - 400% more weld than that attained by any manual or automated TIG welds and you should eliminate weld rework.

 




5G PIPE FILL WELD PASSES
MADE SIMPLE WITH TIP TIG.


TIP TIG pipe fill pass welds are typically made 100 - 400 % faster than regular TIG. No foot control is required, one or two hands can be used to control the torch, lowest weld smoke, no spatter, no slag and no grinding. Look how easy it is to make a pipe weld that is superior weld quality than regular TIG.

In contrast to regular TIG, with TIP TIG there is minimum weld starts and stops. The less oxidized TIP TIG welds are the cleanest welds you will ever see. The TIP TIG weld HAZ produced should be the smallest. The agitated TIP TIG welds should always provide superior side wall fusion with less pore / inclusion defects and the weld stresses should be the lowest.

 




When your manual or auto weld process provides the highest weld quality
with the lowest weld heat, you will see some remarkable weld results


TIP TIG expect manual weld uniformity and continuity, a
small HAZ, minimum weld starts / stops and no defects.


ALL POSITION CODE QUALITY "PIPE WELDS" AND THE CONVENTIONAL PIPE WELD PROCESS CHOICES:

Most global companies who wish to produce all position “code quality pipe welds” will in 2011 be considering the following weld process options. The weld reality is none of these weld processes will provide the consistent, optimum weld quality attained from the TIP TIG process.

a] Traditional Manual TIG Pipe Welds. TIG is approx. 70 years old. This is a process that with moderate currant produces a fast freeze, small weld pool that restricts the manual weld deposition rate potential. With the inability of the manual TIG welder to feed small diameter weld wires (0.035 - 0.045 / 0.9 0 1.2mm) ) at wire feed rates of more than one lb/hr, the manual TIG process has for decades used larger weld wires such as 1/16 to 1/8 (1.6 to 3.2 mm).

The large wire sizes used for those small, manual TIG welds < 300 amps are wire sizes normally associated with high current (400 - 800 amp) Submerged Arc Welds. As there is rarely sufficient weld current for the TIG weld wires utilized, the manual TIG welder will use techniques in which the weld wire is rapidly dipped in and out of the weld. On average about 6 to 8 inches of 3/32 TIG wire is fed into a weld each minute. The resulting manual low TIG weld deposition rates create high labor costs, and the resulting slow TIG weld speeds can generate high weld heat input creating mechanical or corrosion concerns when welding alloys.

Regular TIG requires the highest "welder's skills" and TIG is the only process that requires on many welds the use of two hands and a foot control. The manual TIG pipe weld quality is influenced by frequent wire changes that can generate arc start - stop weld tie in concerns and by the Inconsistent, wire delivery to the optimum arc placement, (the arc sweet spot).

Common manual TIG pipe weld defects are occasional lack of fusion, cracks (often influenced by excess weld heat and small weld sizes, small weld pores and inclusions.

With the greater, focused arc energy and use of inert gases, the regular, manual TIG process should always generate higher weld quality than that possible with the Pulsed MIG and Flux Cored process.


b] Traditional Automated Hot Wire TIG. Add 50 to a 100 amps to a constant fed weld wire into a TIG arc and that provides the fast freeze, small weld with a little more weld energy and you have a process called the Hot Wire (HW) TIG process.

When used on vertical and horizontal welds or on any welds using low to moderate current the applications, the HW process is sensitive to minor changes with the many variables that can influence the arc length and the weld wire to optimum arc plasma placement. To reduce the weld wire to weld sensitivity the automated HW TIG process will typically use an Arc Voltage Control. (AVC). The "weld sensitivity" will on many welds restrict vertical up Hot Wire " feed rates" to weld speeds that frequently will be < 10 inch/min. HW TIG weld deposition (weld speed) potential is increased when the Hot Wire welds are made in the flat weld positions and the part thickness allows weld current above 250 amps.



With the performance requirement for an Arc Voltage Control, the HW process is not suited for manual TIG welding.


Common Hot Wire TIG vertical up, automated weld defects will typically be minor lack of fusion, small pores and inclusions.

Note: The automated Cold Wire TIG process is an even more arc length sensitive process, that while capable of extending the weld arc on duty cycle, is not capable of producing weld deposition rates beyond that attained by a regular manual TIG welder. This process is als simply not suited to manual pipe welds.




FOUR WELD PROCESSES THAT DON'T BELONG IN A WELD SHOP THAT BELIEVES IN DELIVERING CONSISTENT OPTIMUM CODE QUALITY "MANUAL" WELDS..

[1] SMAW (STICK). [2] THE GAS AND SELF SHIELDED FLUX CORED PROCESS. [3] REGULAR MIG SC OR SPRAY. [4] PULSED MIG .


 

 

[c] SMAW - Self Shield Flux Cored Pipe Welds:It's remarkable in 2011 that given the available weld process choices, thousands of global weld shops will still consider the SMAW or the Self Shielded Flux Cored Process for code quality pipe - vessel welds.

With pipe welds that are given 100% x-ray or UT evaluation, the SMAW and Self Shielded Flux Cored processes should be the last processes considered.

SMAW is a weld process that has many " flux concerns" all of which lead to weld issues.

SMAW is a process in which the electrodes will be dramatically different from one consumable manufacturer to another.

SMAW is a process in which you should always expect weld defects at arc starts - stops and at weld tie ins.

SMAW is a process in which it's almost impossible to consistently attain welds without lack of fusion, marginal fusion, slag and pores.

SMAW is a process in which every welder brings different weld skills and techniques to the weld, so it should be no surprise to engineers when procedure weld s do not comply with the weld results from pre-qualified weld procedures.

Common SMAW weld defects are lack of weld fusion - excess porosity - entrapped slag - excess spatter - poor weld tie-ins - undercut - hydrogen cracks and the SMAW welder has to deal with excess hazardous weld fumes.. The bottom line is SMAW is a weld process in which it's impossible to apply effective weld process controls.

Note if you want to know what's wrong with Self Shielded Flux Cored wires, visit the flux cored section at www,weldreality.com.


[d] Pulsed MIG Pipe Welds: The Pulsed MIG process has in the last three decades had many exaggerated electronic weld benefit claims that may help the weld salesman push this process, however this should not be the process of choice for pipe weld shops that want to achieve code quality 5G "fill pass" welds without weld rework.

[] 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 process 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 - 25 %.

[] The Pulsed MIG arc energy is constantly fluctuating between the peak 350 - 450 amps to the low < 100 amps back ground current, these parameter changes again influence the weld energy delivered and make the process sensitive to attaining consistent weld fusion with sluggish alloys.

[] When you evaluate the Pulsed MIG moderate weld deposition rates with pipe welds, it's worth remembering that the greater the weld mass delivered for a specific weld, the greater the weld fusion sensitivity of that weld to the manual induced variables that canl impact the weld delivery and weld energy.

With the pulsed MIG sensitivity to WSO parameter changes combined with the peak to back ground current changes and of course the erratic performance of many pulsed MIG power sources, the pulsed manual weld results on weld joints (walls > 6 mm) subject to x-ray will reveal a few surprises defects such as unexpected lack of fusion, porosity and inclusions.

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 pulsed MIG weld issues such as arc instability, lack of weld fusion on all position welds on parts > 4 mm, excess porosity issues and the difficulty encountered with maintaining essential weld procedure variables with weld equipment that evolves and changes every few months, 15 years later, the same pulsed MIG problems exist. For extensive proof of pulsed MIG process and equipment issues visit my pulsed MIG section at www.weldreality.com..


[e] Gas Shielded Flux Cored Pipe Welds: While superior to the SMAW process, the gas shielded flux cored process will provide extensive weld quality issues with pipe welds. When you pick up that reel of 0.045 flux core wire, be aware that in the average 20 lbs/shift used per welder, there should 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".

Irrespective of the flux cored welder's skills, the weld shop will
have to deal with slag inclusions, excess porosity, excess spatter, lack of weld fusion and excess fumes. This process also encourages manual weave techniques that influence the formation of the mentioned defects.



[f] MIG Short Circuit - MIG STT and MIG RMD Pipe Welds. While these MIG processes are suited to open root pipe welds, the weld manager should be aware that using these processes adds to the complexity of the application and pipe procedures as the welder has to switch to another process for the fill passes.

With these process, there is also concern with attaining consistent pipe root penetration and optimum weld quality with the common root gap and alignment deviations found in the typical pipe shop. This should be a special concern with high alloy 5G root applications where the sluggishness of the weld wire alloys utilized adds to the sensitivity of the root alignment and dimension deviations.

It's one thing to weld pipe open roots with controlled, machined joints and it's another thing to weld a pipe to an elbow that has ID alignment issues or a root gap which is much smaller or larger than 3 mm. While short circuit is well suited to rotated pipe root joints with tight weld gap and joint dimension requirements, the STT and RMD processes can weld roots in any pipe weld position, however these two weld processes have narrow, optimum, weld parameter ranges that are poorly suited to deal with weld root variations and sluggish alloy welds.

Note: With the fast freeze MIG root welds require "reactive gases" which contribute to the common oxide pore defects found in MIG root welds. For extensive real world pipe data on the three MIG processes discussed, visit Ed's www.weldreality.com and select the process in question, or for a low cost purchase the world's most effective MIG - Flux Cored Weld Best Practices and Process Control Training Resources..

In contrast when considering TIP TIG, remember this process can be used as a regular, manual TIG process or Hot / Cold wire manual or automated TIP TIG weld process. therefore TIP TIG is best suited when root variations do occur. For pipe welds or any applications it's worth noting that TIP TIG provides the most extensive amp range available from 50 to 500 amps. With TIP TIG pipe root welds, TIP TIG will provide the highest energy, most focused weld arc, with consistent wire to arc placement. With TIP TIG there is no unnecessary arc starts / stops (tie -in concerns) and no sensitivity to WSO changes as typical with MIG and flux cored. In contrast to regular TIG, the faster TIP TIG weld speeds results in cleaner weld than that attained by TIG or with any welding process.



In contrast to regular TIG, with TIP TIG expect 200 - 500% more
pipe weld production each hour with superior weld quality.



[]
This TIG pipe wire feed, (weld deposition) rate average was 280 inch/min. The above TIP TIG pipe weld was made by a Westinghouse welder. T

[] Y
ou will typically attain 50 - 100% productivity improvements in the root and 200 to 500 % improvements in pipe fill pass deposition rates.

[] Higher TIP TIG wire feed capability enables increased TIG weld current capability. Also in contrast to the regular TIG process, the agitated weld pool and increased TIP TIG weld energy enables superior side wall weld fusion and lower porosity / inclusion content.

[] The TIP TIG Weld Agitation and Hot Wire current is especially beneficial for improving the weld fluiidity with all sluggish alloys such as duplex and stainless.

[] TIP TIG provides much faster manual and automated TIG weld travel rates that enable the capability to always produce any welds with the lowest possible weld heat and the smallest possible HAZ. . With the lowest oxidation potential and the weld agitation, with TIP TIG, you can expect the cleanest possible multi-pass welds with the lowest weld porosity and inclusion content.

[]
With TIP TIG, the weld shop should anticipate producing manual or automated welds and parts with outstanding consistent quality beyond that attained with regular TIG, Pulsed MIG and flux cored.

[] Consistently attaining optimum mechanical or corrosion properties or for example ferrite content in duplex welds, becomes a simplle task with the TIP TIG.

Note: Companies such as Exxon, Westinghouse and WSI (Aquilex) lead the way in the USA developing new 5G, TIP TIG pipe procedures with typical, manual wire feed rates 200 - 400 % greater than that attained by regular manual TIG welders.

 

 


 

WELDING P91. ASME SA 182-F91. ASTM A199 Grade T91.

TIP TIG AND IMPACT PROPERTIES.

LEFT PICTURE. TIP TIG P91 WELDS MADE BY SIEMEN WELDER.

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 original 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.

In contrast to manual regular TIG, the manual TIP TIG semi-automatic process provides an opportunity for the weld shop to implement "uniform weld best practices / process controls and improve the conformance to weld procedure qualifications".

P91 impact values attained from the manual TIP TIG welds. ISO-V(J) at 20° 100-120 J.

 

TIP TIG and P91 Pipe Welds: With traditional TIG used for the root and SMAW for the P91 fill passes, it would take 240 minutes to do each of the critical "P91 pipe joints shown, with TIP TIG it took 65 minutes and the welds were free of defects.

Note: If instead of SMAW you used the traditional TIG process for the fill passes you would likely be applying "excess weld heat" to the heat sensitive joints.

The TIP TIG process was qualified by SIEMENS in Germany for both the P91 root and for the pipe fill passes. For an application like this, depending on the welder, in contrast to regular TIG, the TIP TIG fill pass welds would deposit an average of 200 to 300 % more weld. Note. Using the TIP TIG process Siemens attained the best weld quality and mechanical properties it had ever attained on any P91 applications.

Apart from the superior weld quality from the TIP TIG process, weld shops benefit with a process that gets the job done faster, provides the optimum in weld quality provides the least wear and tear on the the welder with the least weld fumes and of course the parts benefits from the lowest possible weld joules.


 

PIPE WELD PROCESS SELECTION, MECHANICAL PROPERTIES & WELD JOULES RANGE & RESTRICTIONS.

When welding pipes in the 5G position and "optimum weld parameters" are utilized, both the Flux Cored weld process and Pulsed MIG process are highly restricted in the weld joules range they can provide. For example, in contrast to TIP TIG, that 0.045 (1.2mm) Flux Cored wire while welding vertical up may weld at;

Flux Cored. 23 - 25 volts. 140 - 220 A. Typical travel 8 - 15inch/min. Reverse Polarity which ensures
= high localized weld heat build up.

TIP TIG. 12 - 13 volts. 150 - 250 A. Typical travel 8 - 15 inch/min. Electrode Negative enables
= better heat dissipation into the part providing less localized heat.

IT'S EASY TO FIGURE OUT WHICH WELD PROCESS WILL PROVIDE THE LOWEST WELD JOULES.




P91 Steels and other Creep Strength-Enhanced Ferritic Steels: None of the following weld processes, regular TIG - Pulsed MIG - SMAW or Flux Cored can provide the multi-pass weld quality that TIP TIG will deliver from the root to the cap passes.

TIP TIG should always produce the best mechanical properties due to the lowest possible weld heat input. Siemens reports that when welding P91 pipe with the TIP TIG process, it attained the best weld results and the best mechanical properties it's ever achieved.

 




WHEN PIPE WELDING, IT'S BENEFICIAL TO UNDERSTAND WHAT TIP TIG CAN ACHIEVE IN CONTRAST TO THE REGULAR MANUAL TIG PROCESS:

Manual TIG pipe welds are made by welders who use their unique variable skills and techniques while delivering inconsistent wire feed rates into different areas of the small, rapid solidifying weld pool.

Primary issues with the traditional manual TIG process;

[] The inability for the manual TIG welder to ensure their weld wire is always fed consistently into the rapid freeze weld, small plasma sweet spot in the arc and weld, impacts weld quality, weld uniformity and consistency.

TIP TIG always directs the weld wire to the arc sweet spot providing uniform, consistent weld energy.

[] The inconsistent manual TIG "wire feed" rates utilized, impacts weld quality, heat (joules) and productivity.

TIP TIG provides constant fed weld wire that dictates the weld travel rates and regulates the weld joules.

[] The common TIG low deposition rates influence weld labor costs, the weld energy produced and the weld dynamics. The low deposition also impacts the weld current that can be used, the weld travel rates, weld distortion, weld joules input and weld oxidation.

TIP TIG provides deposition rates that are typically 100 - 400% greater than regular TIG welds and the benefits from the increased TIP TIG weld speeds are extensive.

[] The numerous TIG arc starts and stop (weld tie-ins) influenced by the manual weld wire changes,
impacts weld quality, weld appearance and add to weld skill requirements.

TIP TIG eliminates this concern.

[] The high TIG skill requirements for feeding the wire, manipulating the torch and sometimes operating
a foot control, impacts training time required and the adherence to pre-qualified weld procedures.

TIP TIG can use one or two hands on the torch and does not need a foot control so this process is
much easier to use.





TIP TIG INCONEL 800 PIPE . WELDED WITH INCONEL 82 WIRE.
Pipe 10" ID PIPE WITH 3/4 (18 mm) Wall.


Weld Cycle Time 30 - 40 minutes.
Customer used to takes 4 hrs with TIG.

TIP TIG... No brushing. No grinding. No spatter. No foot control. Much less skills than TIG. No weld rework. Constant weld fusion and improved conformance to weld procedures. Cleanest welds from lowest possible oxidation and from lowest weld heat input ensures lowest possible pores and inclusions. Note weld smoke is from vee prep machining lubricants.

 






All Position Nickel Alloy Welds the old fasioned way, please give me a break:

None of the following weld processes, regular TIG - Pulsed MIG - SMAW or Flux Cored will provide the weld quality that TIP TIG will deliver to all Nickel Alloy applications. TIP TIG will produce the lowest possible weld heat and lowest weld oxidation potential. TIP TIG has little concern for sluggish alloys producing welds with superior weld fusion and the best weld and part mechanical / corrosion properties.





TIP TIG PIPE ROOT WELDS.

 

TIP TIG IS WELD PROCESS THAT HAS THE GREATEST TOLERANCE FOR PIPE ROOT DIMENSIONS AND ALIGNMENT DEVIATIONS AND OF COURSE THIS PROCESS WILL THEN PRODUCE THE BEST FILL PASS WELD QUALITY.

 



TIP TIG pipe root welds are typically made at minimum 50% faster than regular TIG and the root weld quality is much higher. Only two start / stops for most 5 G root welds. Note the shiny, uniform, unoxidized root appearance except at the weld end when the torch was raised too quickly loosing the post flow gas. In contrast to the MIG STT - RMD processes the TIP TIG welds have much greater tolerance for root gap and alignment dimension deviations.

The TIP TIG pipe fFill passes are typically made 100 - 400 % faster than regular TIG.

Click here to see the other half of the root.




 

EXAMINE YOUR WELD PROCESS ALTERNATIVES WHEN YOU NEED TO ATTAIN SPECIFIC WELD PART MECHANICALS OR CORROSION PROPERTIES. WHEN IT COMES TO CHOOSING THE PROCESS THAT WILL DELIVER THE BEST WELD QUALITY YOU WILL FIND THAT NO OTHER WELD PROCESS CAN PROVIDE THE CONSISTENT, OPTIMUM WELD QUALITY THAT TIP TIG CAN DELIVER TO ANY ALL POSITION WELD MADE ON ANY ALLOY.






Note: In contrast to pulsed MIG and flux cored, with the TIP TIG process, the weld HAZ should be smaller and the lower weld / clad weld heat input will be easier to control.




Duplex Welds and Wire Stick out Changes: The Ferrite Number in those duplex pipe welds decreases with a "rise in welding current" and an increase in weld speed.

With pulsed MIG and flux cored a a slight decrease in wire stick out can increase the weld current in the range of 10 - 20% decreasing the Ferrite level.

A slight change in gun angle can extend the wire stick out which can increase the Ferrite level.

Note: With TIP TIG welds, torch angle changes will not influence Ferrite levels and there is no wire stick out change.


TIP TIG ON ALL ALLOY WELDS SHOULD ALWAYS PRODUCE SUPERIOR MECHANICALS & CORROSION PROPERTIES.

Think about the many alloy pipe weld benefits when considering TIP TIG. With most alloys welded with traditional TIG, the weld shop primary concern is usually from the slow weld speeds and resulting high weld heat delivered to the parts. TIP TIG enables faster weld speeds which create the opportunity to reduce the weld joules to levels never before attained with any other weld process.

 



TIP TIG Welding a Duplex Heat Exchange Vessel.

When pulsed MIG and regular TIG failed at attaining full penetration open root welds on this duplex heat exchanger, the company selected TIP TIG. The TIP TIG process produced the highest, consistent weld quality with the lowest weld heat and the best possible
duplex properties.





TIP TIG 5G PIPE FILL MADE SIMPLE
.

A TIP TIG weld like this, depending on the wall thickness or pipe diameter is typically made at 100 - 400 % faster than regular TIG. Look how easy it is to make a pipe weld that always produces superior weld quality than regular TIG.

With TIP TIG - lowest weld fumes - no spatter - minimum weld starts - stops - cleaner less oxidized welds - smallest possible weld HAZ along with agitated welds that enable superior
fusion, less pore weld defects and lower weld stresses than regular TIG.

 


 


IF VIDEOS STALL REPLAY TWICE, BETTER SECOND TIME

With TIP TIG you can consistently control the weld wire delivered to the sweet spot in the TIP TIG arc.

TIP TIG is a process in which you can "apply the most manual weld process controls" to any weld application.

TIP TIG PIPE ROOT First time user.

TIP TIG PIPE FILL First time user.

 

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

The TIP TIG weld on right shows more energy than the TIG weld on the left yet the TIP TIG
weld reveals a much smaller HAZ. The TIP TIG weld was done three times faster.
Examine the TIP TIG weld continuity, the weld cleanliness and quality.





WITH ANY MANUAL WELD PROCESS,
WHEN CONCERNED WITH MAINTAINING CONSISTENT
WELD QUALITY, TWO HANDS CAN SOMETIMES BE BETTER THAN ONE:



 

 

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






REGULAR TIG VERSUS TIP TIG WELD DEPOSITION DIFFERENCES.

 

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

[1] Pipe Root
Regular Manual TIG
wire feed rate.

10 inch/min

(70 inch/min)

Manual TIP TIG
wire feed rate increase.


25 - 50%
[2] Pipe Fill

Wall < 3/8 (a)
10 inch/min

(70 inch/min)

100 - 200%
[3] Pipe Fill

Wall > 3/8
10 inch/min

(70 inch/min)
100 - 300%
[4] 1/8 Fillet
10 inch/min

(70 inch/min)
100 - 200%
[5] 3/16 Fillet
Great setting also for all position cladding
10 inch/min

(70 inch/min)
> 150%
[6] 1/4 Fillet
10 inch/min

(70 inch/min)
200 to 400%


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


 

Welding Chrome Moly Pipes - Valves and Fittings on high strength - low temp parts and high temperature - good corrosion property parts that require concern for temper embrittlement, charpy V-notch values or attaining a low X - Factor.

Note (the X-Factor is a formular that measures the welds resistance to the loss of toughness that will occur when the weld is held or slowly cooled through the temp range of 850 - 1100F). All position gas shielded flux cored consumables are often used for these Chrome Moly applications.

[] As TIP TIG provides much lower weld heat input than the regular TIG - Flux Cored and Pulsed MIG processes, TIP TIG can provide the smallest possible HAZ and the lowest possible X Factor.

[] Unlike Flux Cored consumable which may have flux issues such as inconsistent flux composition, or moisture in the flux. With TIP TIG there will never be cause for concern with consumables and hydrogen content.

[] Ref charpy values. In contrast to the flux cored process which always creates concerns for trapped weld slag and excess weld porosity the TIP TIG process enables the cleanest possible welds with less internal defects than any other available manual weld process.

[] While flux cored is not suited for pipe open root welds and this process should provide concerns for the pipe fill pass as extensive parameter changes will occur with a slight change in the wire stick out. In contrast, TIP TIG can provide more weld controls than any other process for any weld position pipe root or fill pass. The bottom line, if the weld consumable is available on a MIG reel it can be used for TIP TIG, so before going down the flux cored path consider the TIP TIG benefits.

[] For those looking at Pulsed MIG on these pipe applications, please note you will not attain the weld quality achieved with TIP TIG and of course this process will weld the root to the cap.

 

 

AS THE EDGE WETTING ON THIS TIP TIG, 40 DEGREE INCLUDED VEE ANGLE
WELD INDICATES, TIP TIG CAN ENABLE A
DRAMATIC REDUCTION IN REGULAR PIPE / PLATE VEE - J GROOVE ANGLES.





TIP TIG. From the pipe root to the fill passes, when you attain the highest
weld quality with good deposition rates you achieve the lowest weld cost.

 


 

TIG WELD COSTS AND WELD DEPOSITION RATES, A SUBJECT
RARELY DISCUSSED IN MANY WELD SHOPS:


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

Weld Question. "Using a regular TIG 3/32 (2.4 mm) carbon steel or stainless wire,
what is the average wire feed length used per minute?

The Answer. The average regular TIG manual wire feed rate using 3/32 (2.4mm )wire was 6 - 10 inch/min. When you convert the average 8 inch/min with 3/32 wire to the 0.035 (0.9mm) wire that's commonly used with TIP TIG, that's approx. 56 inch/min of an 0.035 wire = approx 0.75 lb/hr. With an arc on time of 20 minutes per/hr that results in a regular TIG weld deposition rate range of 0.28 lb/hr, with 2 - 6 inch/ min typical weld travel rates.

 


PIPE WELDS AND REGULAR TIG VERSUS TIP TIG WELD COSTS:

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 - 300 percent more weld wire?



TIP TIG, REGULAR TIG AND PIPE WELD COSTS:

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 deposition rate of 8 inch/min of 3/32 (2.4mm) wire = 0.8 lb/hr.

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 0.27 lb/hr. With a 20 minute arc time, the regular TIG welder when providing pipe fill pass TIG welds deposits on average 0.27 lb/hr.


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 0.27 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 150 inch/min = 2
lb/hr with a 30 minute arc on time thats approx. 1 lb/hr. In contrast to regular TIG depositing 0.27 lb/hr, TIP TIG is providing approx. 300% more weld.

Note on thicker wall or large diameter pipe TIP TIG would deposit 300 - 400% more weld.


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 PIPE WELD 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 PIPE 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 PIPE WELD 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 PIPE 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.





TIP TIG FILL PASSES.

 

TIP TIG. FILL PASS BEFORE CAP. THIS TIP TIG WELD IS BETTER QUALITY THAN MOST COSTLY AUTOMATED TIG WELDS WITH HIGHER DEPOSITION. TIP TIG WIRE FEED AND TRAVEL SPEED CONSTANT. WIRE FEED CONSTANT. MUCH LESS WELD - STOPS AND COMFORTABLE FOR THE WELDER.




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

TIP TIG versus
regular TIG Data.

TIP TIG.

PIPE ROOT QUALITY: TIP TIG Manual Welds. With less arc starts / stops and an agitated weld pool, TIP TIG provides superior root and fill pass welds that are more consistent and uniform.

TIP TIG Pipe root production: Roots typically 50% faster.

TIP TIG Pipe fill production: TIP TIG 100 - 300% faster

TIP TIG horizontal fillets.
200 - 400% faster.

TIP TIG wire / gas cost considerable savings.

TIP TIG PROCESS BENEFITS:

[1] TIP TIG one single optimum process for any metal, any weld and any weld position.

[2] In contrast to all processes, TIP TIG often requires only 3 simple common weld settings for most welds.

[3] On specific stainless open root tank and vessel welds, with "two sided TIP TIG", no back gouging, no grinding and often no high volume purge gas will be required.

[4] In contrast to all weld processes, TIP TIG will produce the least weld fumes and fume removal equipment on most stainless and alloy applications is not required.


TIP TIG PROCESS BENEFITS:

[5] With TIP TIG you can weld with one or two hands with or without a foot control.

[6] 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.

[7] TIP TIG provides the greatest weld heat control with the least oxidation, distortion and the smallest possible HAZ on any application.

[8] 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.

 





FLUX CORED WELD COSTS VERSUS TIP TIG WELD COSTS:

All position gas shielded flux cored versus TIP TIG weld data and weld costs.
With vertical up, 0.045 (1.2mm) E71T-1 wire feed rates usually set between 200 - 350 inch/min (5- 9 m/min) (Ed's wire feed clock method 10 - 12 o'clock), flux cored deposits approx.
5 to 8.5 lb/hr.


FLUX CORED and BRING OUT THE GRINDER:

Flux cored arc on time is influenced by slag and surface defect removal time. Typical hourly flux cored deposition with arc on time of 20 minutes/hr is approx. 1.7 to 2.8 lbs/hr.

With flux cored code welds expect to find weld slag, extensive porosity and lack of fusion weld defects. There will be weld wire quality concerns and extensive spatter. Small wire stick variations with this process can dramatically impact the weld parameters influencing the weld quality and of course always expect with flux cored excess weld heat and smoke.

TIP TIG. PUT THAT GRINDER AWAY:

As TIP TIG should not require any weld cleaning between weld passes, TIP TIG allows an hourly increased arc on time. With a 30 min/hr arc on time, TIP TIG on many common weld applications can deliver 1 to 2 lb/hr typically with no weld defects, no spatter, the lowest weld heat, the lowest smoke and a uniform all position manual weld quality beyond any other weld process.

Pipe fill passes and TIP TIG versus Pulsed MIG. It's this simple, the TIP TIG process can compete with all position pulsed MIG deposition rates and arc on times while producing superior weld quality without the pulsed porosity levels and with superior weld fusion. Also TIP TIG enables lower weld heat, less distortion and the lowest weld fumes.

 



 

FOR THOSE WANTING TO IMPROVE THEIR MIG AND FLUX CORED WELDS: MIG and Flux Cored accounts for > 80% of the welds daily produced. In the majority of global weld shops you will find welders "playing around" with the weld parameters and when weld advice is required the weld shop too frequently turns to a weld salesman. If I was to ask 10 welders one of the fundamental Weld Process Control questions in this weld test, I would get 10 different answers. If I was to ask any responsible weld decision the cost of a common 1/4 (6mm) fillet weld I would get a confused look this is the way it is in 2011 and this is the way it was 40 years ago. With the common lack of MIG - FCAW process controls and lack of best weld practices you create an environment in which its rare when the daily manual and automated weld quality - productivity is optimized.

If you manage welding and believe you can do so effectively without weld Process Control knowledge and the implementation of Best Weld Practices, give me a call I would like to find out what planet you are living on.




Ed's Weld Process Controls and Best Weld
Practices Training Resources

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