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

TIP TIG PROVIDES SUPERIOR WELD QUALITY AND LESS WELD HEAT
THAN TIG AND CAN PROVIDE THOSE 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, weld data suited to the application,
weld process controls and consistent weld conformance to the essential
weld variables generated during the 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 typically enables 100 to 400 % more TIG weld per shift







Sept 2009 TIP TIG ARRIVES IN NORTH AMERICA:

Welcome to the USA patent pending TIP TIG process. TIP TIG
is the evolution of the traditional manual TIG process into the world's
first fully functional "semi-automatic" manual TIG weld process:

TIP TIG: In contrast to the regular manual TIG or the other available Hot / Cold wire TIG processes, irrespective of the alloys welded, the semi-automatic TIP TIG process has the potential to consistently provide superior quality welds with extensive increase in weld deposition rates. The faster TIG weld speeds from the TIP TIG equipment results in a dramatic reduction in weld heat that can lead to improvements in mechanical and corrosion properties.

OPTIMUM WELD QUALITY WITH PRODUCTIVITY: For common 5G manual pipe fill pass welds, the regular manual TIG process when welding vertical up will typically deliver at 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 pipe applications with superior weld quality and weld deposition rates 100 to 300% higher than regular TIG. On typical flat and horizontal fillet welds, we have at this time TIP TIG welders delivering moderate MIG wire feed rates. 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 38 published 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 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 approx. a 1000 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 the trip to Scotland to view a TIP TIG which is a highly modified version of the TIG process. This process has been used in Europe for eight years. 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, part material replacement and unnecessary material handling or machining. These applications will benefit from from TIP TIG as it provides the highest possible weld process controls on any weld, any metal and any weld position.


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 the automated Hot / Cold wire TIG weld defects and provide the weld process improvements necessary for the clad welds on large scale sub sea valve bores. When you eliminate the management, engineering and weld personnel issues from what should be a highly controlled automated hot / cold wire TIG clad weld applications, you get into the application and the weld process issues and the effectiveness of the applied WPQ, WP and Weld 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 welds and that surface must be completely free of any weld defects. When using the highly controlled automated traditional 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 many of you 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 clad weld quality requirements. The BP clad weld specifications for some of their sub sea valves required that Cameron achieve
"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:

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

The weld reality for most global companies who wish to produce all position “code quality welds” will be that they are 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 process are extremely sensitive and easily influenced with minor changes in the many variables that can influence the weldability. Due to the weld operation sensitivity, these processes are rarely used for all position manual code quality welds, and if used you will typically find the weld process sensitivity restricts 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 exaggerated electronic weld claims, inconsistent arc energy, a process that often results in 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: When welding steels and alloys, the traditional TIG process has been the first process choice for most companies wishing to minimize weld rework. The Achilles heel of the traditional manual TIG process has been the inability to establish effective weld process controls. Most manual TIG welds will be made with different skills and techniques and inconsistent wire feed rates as the TIG welders deliver their weld wire into the small, fast solidifying weld pool.

The regular TIG weld wire delivery variations, frequent start stops and very low TIG deposition (low travel) rates can result in weld and part issues. The traditional TIG low weld speeds on specific applications will lead to high weld heat and can be the cause of mechanical or corrosion issues, excess weld oxidation or part distortion. It's also an important point to remind weld personnel that the manual TIG process has typically 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 TIG process for steel and alloy welds could have a dramatic cost and quality impact for many in the welding industry.

 

THE PATENT PENDING TIP TIG WELDING PROCESS.

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 TIP TIG weld is made 100 - 300% faster than manual TIG and would also be faster than the the same welds made on an many "automated" Hot wire TIG welds. Faster TIP TIG weld speeds result in a dramatic reduction in oxide formation and weld heat input.	No wire brushing between the welding passes. No grinding required on the approx 60 weld passes. Note the lack of 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.

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.

Sept 2009: THE PATENT PENDING
TIP TIG PROCESS IS THE LOGICAL EVOLUTION OF THE TIG PROCESS:

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


For eight years, TIP TIG has been used by more than 1000 companies throughout Europe. At the 2008 Essen Weld Show, TIP TIG received the award for the show's most innovative welding process. In Sept 2009, TIP TIG USA took responsibility for TIP TIG sales in North and
S. America and Australia.





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 TIG applications are TIG pipe and valve welds and cladding or repairs as required in most global Nuclear installations.

The problem with the automated Hot and Cold Wire TIG processes 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, 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.

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

The bottom line with regular TIG or Hot / Cold Wire TIG is these processes have an Achilles Heel. Each of these TIG processes provides a rapid solidifying small fluid weld pool zone that creates a sensitivity and restrictions to the amount of weld wire that can be delivered.


REGULAR TIG: The heated area weld pool area directly under the regular TIG tungsten tip provides the highest weld surface tension. The weld surface tension gradient causes the fluid in the weld pool to flow from the lower surface tension area at the edges of the pool toward the weld center. The fast solidifying outer periphery of the weld pool (leading edge) is not highly receptive area for receiving weld filler metal.

MANUAL TIP TIG CAN OUT PERFORM MOST AUTOMATED HOT / COLD WIRE WELDS:

THE PATENT PENDING TIP TIG WIRE VIBARATION IMPACTS THE TIG WELD DYNAMICS CHANGING THE WELD SURFACE TENSION AND THE TIG WELD PROFILE. THE MECHANICAL TIP TIG ACTION DECREASES THE TIG WIRE TO THE WELD SENSITIVITY WITH BOTH MANUAL AND AUTOMATED TIG WELD APPLICATIONS

WITH "MANUAL" TIP TIG WELDING YOU HAVE THE POTENTIAL TO OUT PERFORM MANY
OF THE GLOBAL "AUTOMATED" HOT AND COLD WIRE TIG STEELS AND ALLOYS STEELS APPLICATIONS.

WITH AUTOMATED TIP TIG APPLICATIONS, IN CONTRAST TO HOT / COLD WIRE TIG WELDS, TIP TIG WILL REDUCE THE PROCESS SENSITIVITY, ENABLE HIGER WIRE FEED RATES AND PROVIDE
SUPERIOR WELD QUALITY.



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. Diamond Power.

ALLOYS LIKE DUPLEX, INCONELS AND STAINLESS ARE NO LONGER SLUGGISH WHEN USING THE TIP TIG PROCESS. Many things can affect the solidification of a TIG weld. Welding thick components, welding high carbon steels or welding sluggish chrome and nickel steels. The TIG weld surface tension is also influenced by minute impurity changes in the weld wire chemistry. As an example welding with E316 "low sulfur" stainless as indicated in the right bottom photo, (see note) can reduce the traditional TIG weld surface tension which can influence 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 using 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 concern with most alloys presented to a weld.

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.

 

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

USA. SEPT 2009. TIP TIG description: The patent pending TIP TIG wire feeder and water cooled TIG torch feed a Hot weld wire into a TIG arc. The TIP TIG power source provides current to pre-heat the TIP TIG Hot wire and the TIP TIG weld arc generated by the traditional TIG power source.

THE TIP TIG wire feeder provides a mechanical action 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 and that mechanical action on the weld wire creates a wire vibration that passes through the wire into the molten weld.


TIP TIG directs the consistent fed wire into the optimum arc position: The TIP TIG wire is constantly directed to the center of the fluid weld pool and the agitated weld drives the weld core which has the greatest weld surface tension outwards towards the cooler weld fusion boundary. This process provides a weld quality that is unattainable with any other manual or 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 pool receptivity potential.

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


TIP TIG WIRE FEED UNITS. Maintenance supervisors will be glad to know that TIP TIG equipment does not utilize sophisticated electronics. TIP TIG units are readily adapted to all automated weld equipment including robots.

Remember the weld benefits from a semi-automated TIG wire feed are combined with the benefits from an electrode negative TIG power source.

The TIP TIG electrode negative provides optimum weld fusion and the smallest possible weld HAZ which combined with the moderate TIP TIG weld travel rates enable the potential for the least distortion and smallest possible weld heat affected weld zones.

With TIP TIG you do not require a foot control for most welds however if you need 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.

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.



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 process that physically changes the TIG weld pool. In contrast to any available competative process TIP TIG will be easier to operate. TIP TIG offers less sensitivity to weld wire input providing much greater weld deposition rate potential, and TIP TIG will in contrast to any manual / automated TIG process provide superior weld quality.

I recently did a survey of weld personnel at some of the top engineering companies in North America, Westinghouse, General Electric, Siemanns, and Parsons and WSI. The weld question. " Using regular TIG and 3/32 (2.4 mm) carbon steel or stainless wire. In a five minute weld period, what is the average manual wire feed rate deposited each minute over a 10 minute period? The common 3/32 TIG wire feed range 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 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 - 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.

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.

SEND OR BRING YOUR WELD SAMPLES AND TRY THE PROCESS. MAKE AN
APPOINTMENT WITH TIP TIG AT THE PHILADELPHIA NAVAL YARD.

To view the real world benefits of TIP TIG
email Ed@tiptigusa.com or tom@tiptigusa .com

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.

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

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.






A FEW TIP TIG BENEFITS: 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 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 Inconel 625 ID bore weld. The TIP TIG equipment required took up less than 35 sq/ft of floor space. The TIP TIG multipass, automated equipment for bore welds like this would cost approx 75K. To produce this weld took less than 4hrs to develop the TIP TIG weld procedure and produce the 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 Technical Contacts . North and S. America or Australia contact Ed Craig or Tom O'Malley.
E-mail. ed@tiptigusa.com. tom@tiptigusa.com.
Phone Ed at 828 658 3574.






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

[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,
[] 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.

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

PROCESS CONTROLS, WELD DISTORTION CONTROL AND MANUAL WELD CONFORMITY TO ALUMINUM, STEELS AND ALLOY STEELS 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 allys 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 - AICHI SANGYO - TIG WIRE 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, 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 property concerns especially with distortion and impact properties.


TIP TIG UNIQUE WELD QUALITY BENEFITS. The faster TIP TIG weld speeds when combined with electrode negative produce lower weld heat, lower weld oxidization and the smallest possible HAZ. The higher energy agitated TIP TIG welds will have less internal weld defects and on many applications produce less weld stresses. TIP TIG provides many weld benefits that combine to provide the ultimate in weld quality with minimal impact on the base metals being welded.

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 WELDING INDUSTRY THAT ON MANY 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 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 evident. In contrast to the welds attained by TIP TIG, the pulsed MIG process with it's wire stick out sensitivity and high weld voltage requirements can never attain the weld quality, the mechanical or corrosion properties attained by TIP TIG.

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
PULSED MIG	23 28	100 - 300	No	Required	Negative	Not Capable	Poor
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 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 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 them and avoiding costly weld rework. It looks like we are heading back to TIG for both the root and fill passes, which brings up the question about TIP TIG, Regards TW:

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

[] TIP TIG enables much lower weld volts which combined with the 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 enables the widest welding amp range dramatically increasing the all position weld application potential,
[] TIP TIG enables amp ramp up/down data that provides superior quality on weld starts / stops and
weld tie ins.
[] TIP TIG is not influenced by the common MIG wire stick out changes.
[] TIP TIG always provides superior weld fusion and superior weld controls with less internal weld defects,
[] TIP TIG will always provide superior all position welds.
[] TIP TIG. Weld spatter is never a concern.
[] TIP TIG has no concern for sluggish alloys.
[] TIP TIG can reduce pre-heat requirements as much as 50%. If you clad or hard face take note.
[] TIP TIG has the lowest possible weld oxidation potential and will always produce cleaner
welds on alloy parts
[] TIP TIG typically never requires weld grinding and rarely requires weld cleaning.
[] TIP TIG 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 can 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.






You know with flux cored 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.