TIP TIG USA is responsible for sales in North & South America and Australia. TIP TIG is located at The Philly Navy Yard.
1901 Kitty Hawk Ave. Building 68 Philadelphia. PA. Contacts at TIP TIG USA. Ed Craig and Tom O' Malley.
Call Ed 828 658 3574. Cell 828 337 2695. Web site is www.tiptigusa.com. E-mail ed@tiptigusa.com or tom@tiptigusa.com.

THE EVOLUTION OF TIG IS

TIP TIG ALWAYS PROVIDES SUPERIOR WELD QUALITY AND LESS WELD HEAT
THAN TIG AND CAN PROVIDE WELDS AT MIG WIRE FEED RATES.




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




To daily attain consistent optimum manual weld quality without weld rework,
requires control of the weld consumable as found with a "semi-automatic" weld process,
optimum weld data, weld process controls and consistent weld conformance to
the essential weld variables generated during a weld qualification.



The semi-automatic TIP TIG process is the only weld process that can continuously
enable conformance to any manual or automated weld qualification
procedure. In contrast to regular manual TIG, the TIP TIG process
can provide superior weld quality with increased hourly
weld deposition rates of 100 to 400%.

2010. During the next decade the companies that produce code quality welds will see growth opportunities in the following industries;

[1] Power plant construction and repairs.
[2] Oil & Nat Gas applications.
[3] Green applications.
[4] Defense / Aerospace applications.
[5] Medical industry applications.
[6] Electronic industry applications.

A common denominator with the above industries is the fundamental necessity for weld decision makers to deliver consistent, optimum weld quality and minimize costly weld rework. In the above industries the two
most common weld processes selected will be the two oldest processes, SMAW (stick) and the traditional seventy year old GTAW (TIG) process.



Regular TIG will be the first choice for welds that require optimum quality. Traditional TIG equipment has changed little during the last six decades and the bottom line is the world's most important welds are daily being produced by a weld process in which "weld process controls" cannot be applied to the wire fed into the weld.

In contrast to regular TIG, TIP TIG is a semi-automatic TIG process in which the wire feed rate and wire feed position into the weld is fully contolled, two features which can provide remarkable weld quality and productivity improvements:

TIP TIG USA 2009: In contrast to regular manual TIG or the automated Hot / Cold wire TIG processes, irrespective of the alloys welded, the patent pending
semi-automatic TIP TIG process has the potential to consistently provide superior quality welds with dramatic improvements in weld deposition rates. With TIG welds when you can increase weld deposition the faster TIP TIG weld speeds can result in an extensive reduction in weld heat that can provide numerous weld and part mechanical and corrosion benefits.

When TIP TIG makes welding Titanium look simple and welds 300 - 400%
faster than TIG without using a trailing shield, you know you have a unique
weld process that's going to provide extraordinary all position weld benefits.

TIP TIG WELDING 3/16 GRADE 2 TITANIUM: When manual TIP TIG welding titanium or any alloy, the weld speeds will be typically 100 to 400% faster than TIG. Note the approx 24 inch/min weld travel speed verified by the U-TUBE second counter. The TIP TIG weld quality / productivity improvements combine with welds that have the lowest possible weld heat input.

FINALY THE WELD INDUSTRY HAS A WELD PROCESS THAT WILL DELIVER OPTIMUM TIG WELD QUALITY WITH MIG PRODUCTIVITY: For common 5G manual pipe fill pass welds, the regular manual TIG process when welding vertical up will typically deliver with an arc on time of 20 minutes per/hr approx.< 0.33 lb/hr. In contrast the manual TIP TIG process is being used on these pipe applications with superior weld quality and weld deposition rates 100 to 400% higher than regular TIG. On typical flat and horizontal fillet welds, TIP TIG will deliver 300 to 600% more than TIG. Examine TIG versus TIP TIG weld production potential table below and view the video section.


Welcome. My name is Ed Craig. Many of you will know me from the 18 years of answering questions in the QA section of the Weld Design and Fabrication magazine, or from one of my three books or 38 articles on MIG and flux cored weld process controls. Hundreds of companies have purchased one of my manual / robot MIG / FCAW process control books and training resources or perhaps you have read the weld section I wrote in the Machinery Handbook.

I have four welding patents in the power and fabrication industries and have provided TIG - MIG and flux cored weld process improvements and process control training for hundreds of companies in 12 countries. In the last four decades, much of my time was spent with weld equipment, weld process and
weld consumable evaluations.

During 2009, I made a trip to Scotland to view TIP TIG. This process is a highly modified version of the GTAW (TIG) process. TIP TIG has been used in Europe for eight years. In Sept. 2009, my business partner Tom O'Malley and I bought this important weld process to North America. The TIP TIG process will change the way the North American weld industry approaches the attainment of quality welds.

Numerous global weld shops will in the next decade face the challenge of welding complex, heat sensitive alloys. In this demanding weld environment managers will want to avoid costly weld rework, material replacement and unnecessary material handling or machining. As TIP TIG provides higher weld quality than any other process and TIP TIG enables the highest possible weld process controls with the lowest possible weld heat input, weld shops now have a solution to consistenly meet their weld goals on any metal.


Management weld objectives will be common in most companies, "consistently deliver the highest possible weld quality with the least amount of weld rework at the lowest costs".


ANY INDUSTRY THAT DEMANDS ZERO TIG WELD DEFECTS SHOULD BE USING TIP TIG: During 2009, one of my consultant projects was as a weld process improvement engineer for Cameron in Leeds. UK. The project was to figure out the root cause of their automated Hot / Cold wire TIG weld defects and provide the weld process improvement recommendations necessary for the clad welds on large scale sub sea valve bores.

With any complex weld applications, you first typically will have to deal with the management, engineering and weld shop culture that are part of the root cause of the weld issues. When dealing with automated, sensitive hot / cold wire TIG clad weld applications, you will get into many complex weld process issues influenced by numerous variables and especially noteable will be the effectiveness of the applied WPQ, WP and the daily weld shop practices utilized.


It's one thing to have an NDT standard that allows specific defects and it's an entirely different situation when you have inconel vertical up and horizontal clad welds that require a machined surface on the clad welds and that surface must be completely free of any weld defects. As Cameron is aware, when using the costly, automated Hot / Cold wire TIG process on specific clad welds, it's quite remarkable the amount of weld pores, inclusions and lack of weld fusion that will be revealed.

As all weld shops are aware, the liability consequences of failed welds and tolerance for internal weld defects is reaching unprecedented levels. Demand for the highest possible weld quality has never been greater. One of Cameron's customers is BP and they lead the oil industry in sub sea weld clad quality requirements. Specific BP clad weld specifications for sub sea valves required "zero weld defects" on the clad machined weld surfaces.

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

 

CODE QUALITY WELDS AND CONVENTIONAL PROCESS CHOICES: Most global companies who wish to produce all position “code quality welds” will in 2010 be considering the following weld process options;

[a] Traditional TIG: The 70 year old, very slow weld speeds with high heat input. Inconsistent weld wire delivery, variable weld techniques and excess weld starts / stops.

[b] Traditional Cold / Hot Wire TIG. These manual processes on vertical and horizontal applications can be extremely sensitive and easily influenced with minor changes in the many variables that can influence the weldability. When utilized on these applications the sensitivity will often restrict the wire feed rates < 120 ipm.

[c] SMAW: The 100 year stick process with the common weld porosity, entrapped slag, lack of weld fusion, excess spatter, excess fumes and many electrode concerns.

[d] Pulsed MIG: The pulsed MIG process with it's exaggeraizted electronic weld claims, inconsistent arc energy, a process that often results in excess weld heat, lack of weld fusion and porosity.

[e] Flux Cored: The flux cored process with the usual slag inclusions, excess porosity and lack of weld fusion and excess fumes.


FOR THOSE FOCUSSED ON WELD QUALITY, TRADITIONAL TIG WELDING HAS BEEN THE FIRST WELD PROCESS CHOICE WITH RESERVATIONS:

< 2O10: In North America, when welding steels and alloys, the traditional TIG process has been the first process choice for most companies wishing to minimize weld rework. The primary two issues with the traditional TIG process has been the low wire feed capability and inability to establish effective manual weld process controls.

Most TIG welds are made by welders using variable skills and techniques and inconsistent wire feed rates as the TIG welders manualy feed their weld wire into a small, fast solidifying weld pool. The regular TIG weld wire delivery variations, the frequent TIG weld start stops and very low weld travel rates combine and influence both the weld and part integrity.

The traditional TIG low weld speeds on specific applications will lead to high weld heat with large heat affected zones (HAZ). Depending on the metal, the excess regular TIG weld heat is often the cause of cracks, mechanical, corrosion issues, oxidation and part distortion. It's also an important point to remind managers and weld personnel that the manual TIG process has always produced the highest hourly weld costs.

Of all the available manual / automated weld processes, the TIG process has for decades produced the highest consistent weld quality and therefore it's logical that improvements to the regular TIG process for steel and alloy welds could have a dramatic cost and quality impact for many in the welding industry.

THE ACHILES HEEL OF REGULAR TIG: The heated area weld pool area directly under the regular TIG tungsten tip provides the highest weld surface tension. The fast solidifying outer weld periphery causes a rapid cooling gradiant of the weld pool that results in a weld puddle which is not a highly receptive area for receiving large amounts of weld filler metal.

To show the weld solidification sensitivity of a TIG weld pool, examine how the TIG weld surface tension is influenced by "minute impurity changes in the weld wire chemistry". For example when welding with E316 "low sulfur" stainless as indicated in the right bottom photo, (see note), the low sulfur content reduce the traditional TIG weld surface tension which influences the formation of weld defects and increases the TIG weld sensitivity to weld wire delivery. When the amount of sulfur in the TIG weld wire is increased by a micro amount using fluxes or higher sulfur filler wires, a slight improvement occurs in the weld's surface tension and arc stability as seen in the regular TIG arc (top photo) on the right.

In contrast to TIG, the TIP TIG process operates with higher weld current and an agitated weld pool and therefore this process has minimal concerns with most alloys presented to the weld and that includes sulfur.

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

Question: Ed. in January 2007, we installed two AMET Inc. XM machine hot wire GTAW systems on which I have programmed over 500 weld pass programs, both cold and hot wire, for non-nuclear applications.  The biggest issue we have with hot wire GTAW is "keeping the weld wire in the very small sweet spot" which was especially difficult when utilizing new welding operators. Would TIP TIG help improve our sensitive, automated Hot wire process? Regards Frank at Diamond Power.

Answer: Frank knows the sensitivity of the weld "sweet spot" and now Frank has the opportuinity to use TIP TIG a process without that sweet spot.

 

WELCOME TO THE PATENT PENDING TIP TIG WELDING PROCESS. TIP TIG A LOGICAL EVOLUTION OF THE TIG WELDING PROCESS:

TIG HAS BEEN AROUND FOR 70 YEARS AND
50 YEAR OLD TIG EQUIPMENT HAS MUCH IN COMMON WITH THE TIG EQUIPMENT USED IN 2010. IT'S TIME THE 70 YEAR OLD PROCESS THAT DELIVERS THE BEST WELD QUALITY EVOLVED. THE LOGICAL EVOLUTION OF THE TRADITIONAL TIG PROCESS IS A WELD PROCESS CALLED TIP TIG:

A brilliant Austrian weld engineer Siegfried Plasch, invented the TIP TIG process. Siegfried found the key to dramatically improving manual and automated TIG weld quality / productivity was not to change the weld transfer but to physically change the weld dynamics.



For eight years, TIP TIG has been used by hundreds of companies throughout Europe.
At the 2008 Essen Weld Show, TIP TIG received the prestigious award for the show's most innovative welding process. In Sept 2009, TIP TIG USA took responsibility for the patent pending TIP TIG sales in North and S. America and Australia.

TIP TIG, ANY METAL, ANY THICKNESS, ANY POSITION.

With TIP TIG you take the slow inconsistent manual wire feed rates out of the TIG process.
With the semi-automatic TIP TIG process, you have the capability to control
the weld wire and produce superior weld quality than TIG while using MIG wire feed rates.

From any weld code perspective,
TIP TIG is considered a "HOT OR COLD WIRE TIG process".



IN CONTRAST TO TRADITIONAL TIG, THE TIP TIG MANUAL ALL POSITION STEEL WELDS,
WILL TYPICALLY PROVIDE A 100 TO A 400% MORE WELD DEPOSITION THAN THAT
ATTAINED BY REGULAR TIG, WHILE PROVIDING IMPROVEMENTS IN THE WELD QUALITY.

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

17- 4PH Base Material TIP TIG team welds a deep J groove weld joint with ER630. 0.035 (1mm) wire.	The TIP TIG Weld Macro Reveals All.
This manual rotary multi-pass TIP TIG weld is made 100 - 300% faster than manual TIG and would also be faster than the the same welds made on most "automated" Hot wire TIG welds. Faster TIP TIG weld speeds result in a dramatic reduction in oxide formation and weld heat input.	On this application we used no wire brushing between the welding passes and no grinding was required on the approx 60 weld passes. Note the lack of weld pores or inclusions, the healthy side wall fusion and very small HAZ.

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

Welding critical components and weld cast repairs:

If you wish to provide the highest quality weld repairs on those
costly cast components no other manual process will compete with TIP TIG.

TIP TIG versus regular TIG Data.	North America Patent Pending TIP TIG.
PIPE ROOT: TIP TIG weld, improved uniform weld quality. PIPE FILL: Depending on the weld position, manual TIP TIG is typically 100 - 250% faster than TIG on most pipe fill passes while providing superior weld quality. FILLETS: Typically TIP TIG will be 200 - 300% faster than TIG for most fillet welds and superior weld quality. CONSUMABLES: TIP TIG dramatically lowers both weld wire and gas costs.
TIP TIG WELD PROCESS BENEFITS: [] TIP TIG one single optimum process for any metal, any weld and any weld position. [] In contrast to all processes, TIP TIG will require only 3 simple common weld settings for all weld and alloy applications. [] On many stainless open root tank and vessel welds, with TIP TIG, no back gouging, no grinding and often no high volume purge gas required. [] In contrast to all weld processes, TIP TIG will produce the least weld fumes and fume removal equipment on most stainless and alloy applications will not be required.	TIP TIG PROCESS BENEFITS: [] With TIP TIG you can weld with one or two hands and will not need a foot control. [] Manual TIP TIG delivers a weld quality that's very similar to automated welds. Examine the manual TIP TIG weld uniformity and continuity with the videos and pictures at this site. [] TIP TIG provides the greatest weld heat control with the least oxidation, distortion and the smallest possible HAZ on any application. [] The TIP TIG agitated weld pools provide the potential to produce the lowest possible internal weld defects such as porosity, reduce cracking potential and enable lower weld stresses.

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

TIP TIG EQUIPMENT: The TIP TIG power source provides current to pre-heat the TIP TIG Hot wire and the TIP TIG weld arc which is generated by a traditional TIG power source.

The unique TIP TIG wire feeder provides a mechanical action on the weld wire that influences the weld pool. In contrast to regular TIG welds, the TIP TIG wire entering the TIG weld pool is mechanically superimposed with a motion from the unique
TIP TIG wire feeder. The mechanical wire action creates a vibration that runs through the weld wire agitating the molten TIG weld changing the weld pool dynamics.

TIP TIG PROCESS CONTROLS. TIP TIG always directs the constant fed weld wire into the optimum arc position: With controlled wire feed rates, weld tyravel is regulated. Also the TIP TIG constant fed wire is directed to the center of the fluid weld pool. The TIP TIG weld will provide numerous weld benefits that are unattainable from any other manual / automated weld process.


Note: While MIG equipment manufacturers have used electronics to change and control the weld transfer before it gets to the weld, in contrast the unique TIP TIG wire mechanical action dramatically changes the TIG weld pool dynamics and increases the weld wire to weld pool receptivity potential.

Controlled TIP TIG wire placement, increased amps, constant fed wire feed rates, higher TIP TIG weld speeds, electrode negative and the unique TIP TIG weld pool agitation all combine to provide numerous weld benefits for every TIP TIG weld.

WELDING ALLOY WELDS, THE RULES
CHANGE WHEN USING TIP TIG.

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

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

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

[] IF YOU WELD ALLOYS SENSITIVE TO OXIDATION THOSE ALLOYS
WILL BE LESS SENSITIVE.

[] IF YOU WELD PARTS AND DISTORTION IS AN ISSUE THIS PROCESS PRODUCES THE LEAST DISTORTION.

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

[] IF YOU HAVE WELD POROSITY OR LACK OF FUSION CONCERNS, NO OTHER PROCESS WILL PROVIDE BETTER CONTROL OF WELD FUSION WITH THE LEAST POROSITY POTENTIAL.

TIP TIG EQUIPMENT. Maintenance supervisors will be glad to know that TIP TIG equipment does not utilize sophisticated electronics. TIP TIG weld units are readily adapted to all automated weld equipment including robots. The TIP TIG water cooled torches feed weld wire and as with any torch that feeds wire you will occasionally require a new liner. Most companies will have a spare torch and when a torch needs maintenance they will simply UPS the torch back to TIP TIG for maintenance.

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

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

TIP TIG requires simple weld procedures for any alloys and any weld positions: Simply establish the weld current on the regular TIG power source and set the TIP TIG wire feed rate to one of the four common TIP TIG wire feed settings that are applicable to most weld alloy, all positions applications.



TIG AND WELD DEPOSITION RATES IN AN INDUSTRY THAT RARELY DISCUSSES WELD COSTS. I recently did a survey of traditional TIG weld personnel at some of the top engineering companies in North America. The companies included Westinghouse, General Electric, Siemans, Parsons and WSI. The weld question.

" Using regular TIG and 3/32 (2.4 mm) carbon steel or stainless wire. In a ten minute weld period, what is the average manual wire feed rate deposited each minute?
The answer. The average wire feed rate was 8 - 10 inch/min. In the following table I converted the 3/32 (2.4 mm) wire to an 0.035 (0.9 mm) wire to show you the weld wire deposition differences between regular TIG and TIP TIG.

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 - 350%
[4] 1/8 Fillet	10 inch/min (70 inch/min)	100 - 200%
[5] 3/16 Fillet Great setting also for all position cladding	10 inch/min (70 inch/min)	> 150%
[6] 1/4 Fillet	10 inch/min (70 inch/min)	200 to 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.

TIP TIG VERSUS TRADITIONAL HOT - COLD WIRE TIG:

For those not familiar with the traditional automated Hot / Cold Wire TIG, these processes are typically used where the highest automated weld and clad weld quality
is necessary. Common automated Hot / Cold wire TIG applications are TIG pipe and valve welds and cladding or the weld repairs as required in most global Nuclear installations.

The problem with the automated Hot and Cold Wire TIG process is no matter what type of sophisticated TIG power source is utilized the automated TIG process will produce welds with a small fluid weld area and the rapid solidifying TIG welds will have low surface tension.

The regular automated Hot Wire TIG process is very sensitive to weld wire delivery especially when welding horizontal and vertical up welds. For these welds, the traditional automated Hot / Cold wire feed rates will be restricted to typically 60 - 160 inch/min (1.5 - 4 m/min) and usually to control these welds, automatic Arc Length Voltage Controls are often necessary.

Many companies will purchase the costly automated Hot / Cold wire TIG process to weld deep "J" groove applications or provide welds or cladding for large valves. With the automated horizontal or vertical up welds, depending on the arc on time, 1 to 3 lb/hr is typical. From a weld quality perspective, automated, multi-pass Hot / Cold wire TIG welds may have porosity, small oxide inclusions and small areas of lack of fusion.

Important Note: Most weld process experts would define many automated Hot / Cold TIG applications as welds made with a "highly sensitive weld process" and these processes are poorly suited to "manual"
TIG welds. As the unique TIP TIG process changes the traditional TIG weld dynamics, the TIP TIG process dramatically reduces the weld wire delivery sensitivity and TIP TIG therefore allows "manual TIG welds" at greater weld deposition rates than those attained by most global, automated Hot / Cold wire TIG weld systems.

The regular Hot / Cold Wire TIG welds like regular TIG provide a rapid solidifying small fluid weld pool zone that creates a "sensitivity" for the weld operation and
with many automated welds, restricts the amount of weld wire that can be delivered to the welds.

Remember, in contrast to regular TIG, it's not only more weld from TIP TIG,
the TIP TIG weld quality should always be superior to regular TIG.



IF VIDEO SLOW OR PAUSES PLAY TWICE FOR BETTER RESULTS.

CARBON STL TIP TIG 2 G PIPE ROOT.	CARBON STL TIP TIG 2 G PIPE FILL.
WITH TIP TIG, SAME UNIFORM OPTIMUM ROOT QUALITY FROM 6 TO 12 O'CLOCK. DRAMATIC REDUCTION IN WELD STARTS AND TOPS. CLEANER LESS OXIDIZED ROOT WELDS. WITH CONTINOUS WIRE FEED ALL TIP TIG ROOT WELDS ARE MADE FASTER THAN ANY TIG WELDER CAN PRODUCE.	SUPERIOR SIDE WALL FUSION FROM THE TIP TIG AGITATED WELD WETTING & CLEANER WELDS WITH LESS PORE DEFECTS. NO WELD START STOPS FROM 6 TO 12 O'CLOCK. DEPOSITION RATE OF TIP TIG FILL PASS WELDS ARE TYICALLY 100 - 300% HIGHER THAN THAT ATTAINED WITH TRADITIONAL TIG.

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


We also invite you to visit our facility and bring or send your weld samples.
Make an appointment: E-mail Ed@tiptigusa.com or tom@tiptigusa .com

COMPANIES WHO HAVE ATTENDED THE TIP TIG WORK SHOPS.

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

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

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






TIP TIG AND SUPERIOR ALL POSITION WELD QUALITY: In a 30 minute hands on demonstration, the TIP TIG team can show you on any code quality application how the TIP TIG process will provides superior, all position TIG weld quality on any metal.

TIP TIG AND INCREASED WELD PRODUCTIVITY: We are now establishing TIP TIG manual weld procedures that depending on the pipe wall thickness will in contrast to traditional TIG welds typically produce an hourly, all position weld deposition increase of 100 to 400%.

TIP TIG AND SMALLER EDGE PREPS: With TIP TIG you can provide further dramatic weld cost reductions on many applications by enabling a decrease in traditional pipe and plate VEE or J groove edge preps.

TIP TIG LESS WIRE, LESS GAS COSTS: With TIP TIG, in contrast to traditional TIG you can expect approx. 25% reduction on the TIG weld wire costs and as TIP TIG welds much faster than regular you typically will require 25 to 50% less weld gas.

TIP TIG AND VESSEL PURGING: On many weld applications, TIP TIG enables manual controlled open root "two sided welds" on specific alloy tanks, vessels and plates, two sided TIP TIG root welds can eliminate vessel purging or the common costly closed root back gouging / grinding.


TIP TIG and LOW COST WELD AUTOMATION:
It's this simple, there is no other weld process that will provide the automated weld quality that TIP TIG will produce. Take a look at this untouched Inconel 625 ID bore weld. The TIP TIG equipment required took up less than 35 sq/ft of floor space. The TIP TIG multi pass, automated equipment for bore welds like this would cost approx 70K. To produce this weld took less than 4hrs to develop the TIP TIG weld procedure and produce this first off weld. The typical TIP TIG weld speed on these parts would be between 15 and 20 inch/min. No matter how complex the weld application or the alloy welded, with TIP TIG there is no "playing around" with weld data for procedures. The first parts you produce should be superior to any TIG, pulsed MIG, CMT or Short Circuit welds you are producing for ID - OD welds.

EUROPE: One of the worlds largest TIG applications welded with TIP TIG, (see info below). We are pleased to report Ziemann Bauer Germany, the world's market leader in building breweries recently purchased > 20 TIP TIG units for welding it's stainless and duplex welds. Cheers Ziemann.

NORTH AMERICA: We are pleased to report that Welding Services (Aquilex) - Westinghouse - Exon and TI Fab have now ordered products.

TIP TIG Sales / Technical Contacts. North - S. America or Australia contact Ed Craig or Tom O'Malley.
E-mail. ed@tiptigusa.com. tom@tiptigusa.com.
Phone Ed at 828 337 2695.






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

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

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

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

[] THE SMALLEST HAZ,
[] SUPERIOR MECHANICALS,
[] SUPERIOR CORROSION PROPERTIES,
[] LESS WELD OXIDATION,
[] SUPERIOR WELD FUSION,
[] LESS DISTORTION,
[] REDUCE WELD STRESSES,
[] LESS CONCERNS FOR CRACK FORMATION,
[] ENABLE THE RELEASE OF MANY INTERNAL PORES & MICRO DEFECTS.

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

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

[6] ON MANY TIP TIG TANK, VESSEL, PIPE AND PLATE WELD APPLICATIONS, NO FILLING THE VESSELS WITH PURGE GAS, NO ROOT STEEL BACKING, NO GRINDING OR BACK GOUGING AND NO CERAMICS.

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

[8] TIP TIG IS ESPECIALLY BENEFICIAL WITH ALLOYS AND WILL PROVIDE SUPERIOR WELD RESULTS ON TITANIUM, INCONELS, COPPER, STAINLESS, STELITES - DUPLEX AND ON ALL ALLOY AND STEEL WELDS.

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

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

SPACE - AIRCRAFT - POWER PLANTS - OIL - DEFENCE - GREEN INDUSTRIES
No matter how complex the alloys welded,
with TIP TIG there will always be less potential for defects and deformation.

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

WELD PROCESS CONTROLS, WELD DISTORTION CONTROL AND MANUAL WELD CONFORMITY TO ANY ALUMINUM, STEEL OR ALLOY WELD QUALIFICATION PROCEDURES SHOULD BE IMPORTANT TO WORLD CLASS ORGANIZATIONS THAT ARE INTERESTED IN DAILY PROVIDING CONSISTENT, UNIFORM, OPTIMUM WELD QUALITY.

If your organization TIG welds Inconel Alloys - Aluminum - Stainless Alloys - Cobalt alloys - Molybdenum alloys - Titanium Alloys - Stellite Alloys - Duplex Alloys - Hastelloy Alloys - Any Haynes and Waspaloy Alloys HSLA, or High Carbon steels, the bottom line with the TIP TIG process, you will always attain superior weld quality, superior base metal mechanical and corrosion properties. If in the past you have been concerned about an alloy's that is sensitive to weld cracks we can guarantee you that the TIP TIG process will provide the least potential to form cracks. If you oxy fuel hard face with alloys such as STELLITE 1 and very high pre-heat temperatures are required you can now produce these same welds with TIP TIG and you can anticiapte a 40- 50% reduction in both pre heat and interpass temperatures. It's nice to know that while you are providing weld solutions to the world's most complex alloys, in contrast to TIG with the TIP TIG welds your weld costs should be 100 to 500% less.

While some weld companies would be happy with a 50% increase in
TIG or SMAW weld productivity, we can show you how to attain 100 to 500%


CK WORLD WIDE and AICHI SANGYO TIG WELDING SYTEMS:
NONE OF THEIR TIG PRODUCTS CAN DELIVER THE MANUAL TIG WELD
QUALITY AND PRODUCTIVITY THAT TIP TIG WILL DELIVER.

In contrast with carbon steels in which the oxides and inclusion typically rise at a fast pace to the weld surface, with the sluggish composition of the chrome nickel and nickel alloy welds, micro contaminates, oxide inclusion and gas pores are more likely to become trapped in the welds providing unacceptable NDT results. The sluggish nature of many costly alloy welds like duplex can also cause lack of weld fusion especially on parts > 5 mm. Lack of weld penetration and internal weld defects can be a location for stress concentration. With regular TIG slow travel rates and the excess weld heat generated, you often will have mechanical concerns especially with strength, stresses, distortion and impact properties.

A TIP TIG WELD FACT: IT TAKES TWO TO FOUR TIG
WELDERS TO DO THE WORK OF ONE TIP TIG WELDER.

WHAT ABOUT PULSED MIG? THERE IS A GENERAL CONCENSUS THROUGHOUT THE WELD INDUSTRY THAT ON MANY PULSED MIG WELD APPLICATIONS > 5mm, YOU CAN ANTICIPATE LACK OF FUSION OR POROSITY ISSUES.

For the last three decades, many of the major global weld equipment manufactures have focused on the installation of electronic bells and whistles in their MIG equipment. In many instances the power source electronics have dramatically increased pulsed MIG equipment prices, yet the REP Pulsed MIG equipment will typically have little impact on optimizing the MIG weld quality on many all position steels and alloy welds.

When you evaluate the REP Pulsed MIG weld fusion with the easy to weld horizontal steel fillet welds on steels > 5 mm, you will often find the side wall fusion is either "lacking or marginal" and porosity is often evident. Weld polarity plays an important roll in the weld / part quality you will attain.

[] In contrast to reverse electrode positive (REP) pulsed MIG in which most of the weld heat is in the arc, on the same welds attained by electrode negative (EN) TIP TIG, the EN TIP TIG preheats the fusion area increasing side wall weld fusion.

[] Pulsed MIG has a much lower arc temperature than TIP TIG so you can anticipate more weld porosity with Pulsed MIG.

[] With the Pulsed MIG process you will have wire stick out sensitivity changes during the weld and the stick out variations will provide dramatic changes to the weld parameters.

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

[] In contrast to TIP TIG, Pulsed MIG requires much higher voltages than TIP TIG and the REP imparts much more heat in the welds HAZ.

Note: See the pulsed MIG section and the pulsed MIG equipment sections at this site for extensive evidence and the root cause of the pulsed MIG process and equipment issues.

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

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

Feb. 19 2010: E-Mail. Ed. Reference our recent experience with Miller Pipe Pro MIG for the root / fill passes. In controlled welding conditions using the 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 weld defects did not show up in radiographs but were obvious in the radius side bends. On the ID the root bead was through, but narrow in spots. Although the defects were corrected at the PQT they came back with a change of MIG wire from a different wire manufacturer. Mechanical testing was done for the same pipes with the Miller Pulsed MIG for the fill and we used TIG for the root pass. The TIG side bend tests had zero defects, however the Miller pulsed MIG process had four coupons  with an area beside the root bead that opened up.

The bottom line Ed is we don't have a lot of confidence in either the RMD process for the roots or the pulsed MIG process for the 5G fill passes. The Miller sales rep claimed an apprentice welder can make pipe welds with this equipment with two days training. As you well know Ed, it's not making the pipe welds that is the concern, it's having many welders consistently passing the NDT requirements and us avoiding 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 t TIP TIG. Regards TW:

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

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

[] TIP TIG in contrast to pulsed MIG enables the widest welding amp range dramatically increasing the
" all position" weld application potential.

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

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

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

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

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

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

[] TIP TIG in contrast to pulsed MIG can reduce pre-heat / interpass requirements by as much as 50%.
If you clad or hard face take note as TIP TIG will produce less cracks.

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

[] TIP TIG in contrast to pulsed MIG typically never requires weld grinding or brushing.

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

Pulsed MIG will never attain the weld quality of TIP TIG

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





Many weld defects are not caused by weld personnel.

You know with flux cored wire issues that there are
no weld wire or weld quality guarantees.




WELD SHOP GRINDING AND WASTE:


Does it make sense to pay a welder $25/hr to
weld and then pay the welder to grind out the weld?


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

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

Manual TIP TIG 309 stainless. 3.2 mm fillet 25 inch long. Believe me this picture
does not do this weld justice. With a TIP TIG weld you should never need a
grinder. Too see actual finished TIP TIG FILLET weld video click here.

 

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

darren@mathiesonweld.co.uk






Continue TIP TIG Manual Page 2.