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

TIP TIG Welding

 


TIP TIG PIPE - VALVE - VESSEL WELDS.


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

TIP TIG USA:
1901 Kitty Hawk Ave.
Building 68. Naval Yard.
Philadelphia. PA 19112.
Pho 215 389 7700.




AFTER SIXTY YEARS, THE EVOLUTION OF TIG IS CALLED TIP TIG
.



During 2011, the largest sub sea oil company in China, the China National Offshore Oil Corporation. (CNOOC) was looking for a weld solution for its 20 mile sub sea pipe. The pipe was clad at the ends with Inconel. The automated clad welds and the manual circumferential weld were made on barges at sea. CNOOC engineers had tried regular TIG and the most sophisticated pulsed MIG equipment available for the inconel welds and the weld results were not satisfactory. With a few hours of weld evalution at our Philadelphia facility. the Chinease engineers selected the TIP TIG process for both the 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 ALL THE 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 - COLD WIRE TIG, FLUX CORED,
PULSED MIG, RMD AND STT PROCESS CANNOT COMPETE WITH TIP TIG.



PIPE WELD BENEFITS FROM THE TIP TIG PROCESS:

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.

Visit the manual and home section to find out how TIP TIG works.


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


Note TIP TIG manual weld uniformity and continuity,
the minimum HAZ, minimum weld starts / stops. X- Ray = no defects.


ALL POSITION CODE QUALITY PIPE WELDS AND
CONVENTIONAL 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 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 be minor lack of fusion, small pores and inclusions.

Note: The automated Cold Wire TIG process is an even more 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 simply not suited to manual pipe welds.



TWO WELD CONSUMABLES THAT DONT BELONG IN A WELD SHOP
THAT BELIEVES IN DELIVERING CONSISTENT QUALITY WELDS;
SMAW (STICK) ELECTRODES AND SELF SHIELDED FLUX CORED WIRES.


[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 the TIP TIG process expect 200 - 500% more pipe
weld production each hour with much 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 tradition
al 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
= high localized weld heat build up.


TIP TIG. 12 - 13 volts. 150 - 250 A. Typical travel 8 - 15 inch/min. Electrode Negative
= better heat dissipation, less 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.

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:

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.




TIP TIG AND CONTROLLING FERRITE WITH DUPLEX WELDS:


CONTROLLING FERRITE WITH DUPLEX PIPE WELDS IS MADE SIMPLE WITH THE 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.

Note, As indicated in the left report,the first time (no play around) ideal ferrite volume percentage consistently attained with the TIP TIG process as indicated in the report shown on the left.

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


WHEN TRYING TO ATTAIN CONSISTENT OPTIMUM FERRITE LEVELS WITH DUPLEX WELDS OR CLADD WELDS, IT CAN BE FRUSTRATING WITH PULSED MIG AND GAS SHIELDED FLUX CORED. IN CONTRAST ATTAINING OPTIMUM CONSISTENT FERRITE VOLUME IS SIMPLE WITH TIP TIG. WITH TIP TIG THERE IS NO WELD FUME CONCERNS, NO WELD SPATTER AND TIP TIG CAN DO THE ROOT TO ANY NUMBER OF MULTI-PASS WELDS IN ANY WELD POSITION.

Control of Ferrite in Duplex is essential to achieve optimum corrosion resistance & mechanical properties

Dup
lex Welds. The Ferrite Number decreases with the rise in heat input and dilution. Both pulsed MIG and flux cored will typically provide higher weld heat input than a TIP TIG weld.

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 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.



Weldind 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 WELD PROCESS, WHEN CONCERNED WITH MAINTAINING CONSISTENT
WELD QUALITY, TWO HANDS CAN 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, 35 - 45 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.



IN AN INDUSTRY IN WHICH IT''S DIFFICULT TO FIND SKILLED WELDERS.


TAKE NOTE THAT ON MOST TIG APPLICATIONS IT TYPICALLY TAKES
2 TO 3 TIG / SMAW WELDERS TO DO THE WORK OF ONE TIP TIG WELDER.




TIP TIG THE WELDERS CHOICE
FOR PIPE WELDS.
REGULAR TIG AND PULSED MIG CANNOT DELIVER THE MANUAL OR AUTO PIPE WELD QUALITY ATTAINABLE FROM TIP TIG.

 

Depending on the pipe diameter and wall thickness, TIP TIG pipe fill passes typically provide 100 - 500 % more weld than a manual TIG welder.

With TIP TIG foot controls not required. TIP TIG enables one or two hands on the weld torch. With TIP TIG you can eliminate the skills required to feed the weld wire.
The TIP TIG wire is always directed in the optimum arc location. Manual weld travel rates are more constant. Lower weld heat, less fumes.

Manual TIP TIG ROOT pipe welds typically
made 50% faster than TIG and the welds. These weld should look like automated pipe welds.




More TIP TIG info E-Mail ed@tiptigusa.com or call 828 337 2695.

For the best way to optimize MIG and flux cored welds visit www.weldreality.com


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