Why TIP TIG is the Evolution of TIG.

2018: TIP TIG, much better weld quality than TIG. Easier to use than TIG. 200 to 400% lower labor costs than TIG, and always provides the best possible metallurgical properties. It's been available for more than 12 years and your company is still not using it. What does that say?

TIP TIG was invented by Plasch in Austria. Ed now Em Craig, (weldreality.com) who wrote this blog, found TIP TIG in Scotland thanks to D.Matherson. Ed attained the TIP TIG rights from Plasch for North America and Australia. In 2009, Ed connected with friend and business partner, Tom O'Malley. Together in Philadelphia Ed and Tom created TIP TIG USA.

2018: After studying the traditional DCEN TIP TIG process versus DCEN TIP TIG now for more a decade, the TIP TIG & TIG comparison data at this site is based strictly on my weld process and application observations. As I receive no remuneration for presenting this extensive, original, copyright protected data, I would appreciate it that if you wish to copy or present this origional data, please first obtain my permission. Em Craig at ecraig@weldreality.com.



Rev. Jan 16. In 2019, to understand the not so new DCEN TIP TIG’s weld process capability, it helps if the weld decision maker understands what’s happening in the TIP TIG video below.


TIP TIG. A Unique Weld Transfer with Unique Weld Benefits.

Take a close look, see if you are aware of the important differences that will be taking place between this manual TIP TIG weld with it’s unique arc, plasma and wire melt, in comparison to what is happening in the traditional, manual  DCEN TIG weld, (below).  Would you also know the differences with this TIP TIG weld and an automated  DCEN Hot Wire TIG weld? And for that matter, could you explain the weld differences that would be occurring  with the semi-automated DCEN TIP TIG weld and a semi-automated, Reverse Polarity, Pulsed MIG weld?  

 

To evaluate the unique TIP TIG weld process, and also it’s broad manual and automated weld application attributes and benefits, requires “without the usual  influence of sales advice,  a comprehensive understanding of the differences and the positive and negative attributes of  these three related processes.

[1] Traditional DCEN TIG.
[2] DCEN Hot Wire TIG.
[3] Pulsed MIG.

For those that use traditional  70 year old DCEN TIG, (GTAW) process,  weld  process complacency is understandable, but not acceptable.  

For seven decades, DCEN TIG provided the best manual arc weld quality. This process has had  a simple weld amp control, however it required the highest welder manual welder skills, and also produced the highest manual arc weld costs.

 

For decades, those that know me will be aware that I have been more than a little frustrated with our, entrenched “why change the way we have always done it,” weld industry. So I will  start this new blog on the now approx. 12 year old TIP TIG process, by asking a question.

“How long do you believe it should take experienced global weld decision makers to recognize the benefits derived from a new arc weld process, especially with an arc weld process such as TIP TIG: 

[] TIP TIG enables the lowest possible all position welder skills, 
[] TIP TIG provides superior weld quality than manual TIG, automated Hot Wire TIG and the Pulsed MIG process.
[]  TIP TIG provides  both the highest possible weld quality and lowest possible weld heat that enables extraordinary weld & part metallurgical benefits never before attained, 
[] TIP TIG enables the lowest possible weld stresses and distortion,
[] TIP TIG enables the lowest possible weld fumes,
[] TIP TIG dramatically lowers hourly labor costs from an increase in TIG weld productivity that’s typically in the range of 200 to 400%,
[] TIP TIG is the first semi-automated and fully automated arc weld process that has the potential on most all position, steels, alloy steels and alloy welds, to eliminate the need for weld rework.

Please remember with arc weld process comparisons, you are not a weld professional if you have to “play around” with the weld controls.  Also you are not a weld professional if you have to seek weld advice from a weld salesman. Let’s face it, weld professional or not, there should be n0 room for weld process confusion, weld process ignorance or weld process apathy in any business in which welding is an important process.


As I write this in 2019, I hope this blog takes the process and application confusion out of the TIP TIG process. I also hope that the following data will speed up the acceptance of  this important process and enable weld decision makers to be aware of  where DCEN TIP TIG belongs throughout the global weld industry.


EVERY WELD SHOP BENEFITS FROM A FOCUS ON WELD PROCESS CONTROLS AND BEST WELD PRACTICES.

On thes process subject, I recognize that while manual and robot MIG robot weld process  ignorance maybe an acceptable way of  life especially with many of the front office weld decision makers in the global Auto & Truck industry. However weld process controls and best weld practice ignorance should not be considered acceptable in weld shops who have a mission to provide the best possible code quality welds, weld shops who have an interest in enhancing their weld capability and reputation, weld shops who have an interest in reducing their weld costs and increasing their profits. 

You don’t need to be a rocket scientist to figure out that lack  “arc weld process controls & best weld practice expertise,”  could influence and impede the acceptance of  any new weld technology such as the TIP TIG process.  Another influence on the global impedance of  the TIG TIG process, is the general reliance of  millions of weld shops on weld salesmen for weld equipment and process advice. 

When a company has to rely on salesmanship for technical guidance with the processes that are an essential part of their mfg.  you know where that can possibly lead. 


SALES INFLUENCE ON LACK OF WELD PROCESS EVOLUTION.
 Many i
n the weld industry will rely on weld sales rep for process advice. That rep will often have a degree in English or History and usually the rep will have never run a weld shop. It’s not difficult to comprehend that much of the traditional DCEN TIG and the Pulsed MIG weld equipment purchased over the last three decades, will have been purchased as a result of weld  sales influence and the too frequent, dubious product marketing claims. The weld equipment purchased would often be loaded with costly, useless electronic bells and whistles that did more for the weld equipment manufacturers profits,  than it did to enhance the  weld quality or productivity.

Salesmanship also dramatically influenced  the purchase of  weld consumables. For example, instead of the four MIG gas mixes required for all global MIG welds, we have over 40 mixes to choose from. (Ed – Em, was a key writer of the AWS MIG gas specifications). And instead of using MIG wires many companies will use the often unnecessary,  more costly, flux cored or metal cored wires. 

WHEN SALES REPS. ARE REQUIRED TO GUIDE WELD SHOP DECISION MAKERS ON THE IMPORTANT ARC WELD PROCESSES THAT HAVE CHANGED LITTLE IN DECADES, THIS IS USUALLY AN INDICATION THAT THE COMPANY LACKS THE ABILITY FOR WELD PROCESS OWNERSHIP. 

The DCEN TIP TIG process is not about electronic bells and whistles. For the weld current, this process does utilize a conventional DCEN TIG power source thats  combined with a unique, patented TIP TIG wire feed delivery system that creates an agitation effect on the weld wire that’s delivered to the tungsten tip. The TIP TIG wire feed system benefits from “mechanical actions” on the wire feed drive rolls. The reality is TIP TIG does “not require electronics” to derive  the numerous TIP TIG weld application benefits. 


THERE ARE SOME INDUSTRIES THAT SHOULD LEAD. As diverse as the weld industry is, there are certain industries such as Aerospace, Nuclear Defence and Oil that you would think would want to rapidly embrace a new weld process that has broad weld application potential and enable remarkable weld quality improvements with dramatic weld cost reductions.

The following  Spacex vessel will be the world’s largest,  21st Century, Stainless spaceship. Pity it will likely have been welded using 20th Century arc weld processes. 

Its understandable that Elon Musk did not understand the human weld process control – best weld practice expertise required by his arc weld robot workers at his CA Tesla facilities. However with his Spacex company, Musk wants to send humans in this giant stainless beauty on a round trip to Mars in the next few years. Its a pity that its not likely this spaceship will be welded with TIP TIG which is simply the the best available 21st Century,  manual and automated arc weld process, especially when utilized on alloy steels such as stainless.


The weld reality is that it’s more than likely in 2019 that the engineers at Spacex like many of their peers in other Aerospace facilities, will when it comes to arc welding, be utilizing 20th Century
arc
weld technology with arc weld Specifications and  Procedures that were likely established in the 1980s. Lets face it, the high tech industries are not immune from weld process ignorance and apathy, and  someone today in an Aerospace or Defence company will be sitting at some weld meeting and repeating the following,  “look its a weld, so why change the way we have always done it”?


In 2019, in the majority of the major global defence, aerospace, power and oil  companies,  most of the manual, code quality, all position, arc welds will be made using the 70 plus year old DCEN TIG, (GTAW) process. And if not using TIG, they will be using arc weld processes that provide inferior weld quality than TIG, processes such as SMAW, (stick), Pulsed MIG and gas shielded flux cored. These traditional old arc weld processes will in contrast to TIP TIG, provide  inferior manual weld and part quality. Lets face it, with the traditional arc weld processes, when weld X-Ray weld quality is required, costly weld rework  is the expected norm.

THE COSTS OF WELDER SKILLS.  Another manual arc weld issue is that all the traditional arc weld processes will require higher all position welder skills than required with the TIP TIG  process. Welder skills impact weld quality attainment, also high welder skills such as required by TIG, influence the hourly weld labor costs. And lets face it, in 2019, all position, global  skilled weld personnel are in short supply.

What else impedes weld optimization and weld process evolution?  For many companies their QA department is supposed to be a driving force in the attainment of consistent optimum weld quality,


Most weld  QA weld inspection programs in high tech industries are simply not cost effective and rarely enable the best possible weld quality and productivity results.

It’s a  sad engineering comment that the bottom line for most global Fortune 500 companies involved with welds, is for decades, with the general lack of management weld process ownership, most companies have ended up with a costly, weld quality approach.

In most companies,  extensive, costly  weld  QA resources are focussed on Finding Weld Defects rather than on Weld Defect Prevention. It’s ironic that at the majority of companies, most weld supervisors, and the QA inspection personnel responsible for critiquing and finding weld defects, will usually lack the Weld Process Control and Best Weld Practices expertise thats is necessary to Prevent the majority of those Weld Defects.  When the key weld and QA decision makers lack this fundamental process control expertise they are not likely to rush out and embrace new weld technology in which they know even less about.


Its  2019,  and the majority of major Aerospace, Defence Contractors, Nuclear – Power and Oil companies have for more than a decade been using the outdated arc weld processes and not utilizing the weld process controls and best weld practices for their welds. YAWN.

From my perspective, the global Navies, their contractors & suppliers have never really understood Weld Process Controls and Best Weld Practices. For decades, the lack of easy to learn weld process control  expertise, has  especially in global shipyards created billions of dollars in unnecessary weld rework, and I am sure accounted for weld failures deaths that resulted in many deaths.

 

If you owned the weld shop, DO YOU BELIEVE IT WOULD  BE MORE COST EFFECTIVE  FOR THE WELD SHOP TO PLACE IT’S FOCUS ON FINDING OR PREVENTING WELD DEFECTS. 


ATTITUDES: How weld shop attitudes can also affect weld process evolution and progressive weld process changes in weld shops. Lets face it, who has not heard the following two phrases in their weld shop. “Why change the way we have always done it”. Or  what about that old weld shop favorite.  “Can you give me sometime to play around with the weld controls?”

SKILLS: Welder skills also play an important role in new process acceptance.  Traditional TIG for example requires the highest welder skills, and in some weld establishments these skills can create a welder diva mentality whereas the welder proudly proclaims,  “I am a Nuclear TIG Welder” or “I am a Titanium TIG welder”. And so when a process such as TIP TIG comes along and shows that it does not even require a gas trailing shield for those titanium welds, and that TIP TIG also dramatically lowers  all position pipe welding skills, well those TIG welders have to either accept and come to grip with the new easier to use TIP TIG process, and either put their skills to good use with TIP TIG, or sulk and resist change. 


Finally, attaining all position, code quality welds that won’t require weld rework  is a simple requirement with TIP TIG. Any TIG welder that occasionally feels the twinges of aching weld joints, should also appreciate the pipe TIP TIG weld benefits obtained from not having to manually feed a TIG weld wire, with being able to use one or two hands to control their weld torch, and not requiring a foot amp control.

So what do you think is unusual in this TIP TIG weld application? Apart from the use of one hand, no foot control, no spatter, no smoke, minimal skills required, and each hour the three to four hundred percent increase in TIG weld being produced for the weld shop. What you don’t see is the superior weld fusion and the lowest weld porosity potential. What you also don’t also see is always the lowest possible distortion, the lowest possible weld  stresses and the  best possible metallurgical results. With TIP TIG, the application and the weld position is usually irrelevant. P91 – Duplex – Inconel – Stainless – Hastelloy – Titanium – Carbon steels and all High Strength steels, it does not matter. Also  it also does not matter if the welds are Manual or Automated, if the  parts are 16 gauge or any thickness. 


SO WHERE DO YOU GET THE WELD PROCESS CONTROL RESOURCES? After assisting over 1000 companies in 13 countries with their weld issues. From my perspective, it  does not matter if you work in the front office, the QA office or on the weld shop floor, the first management / engineering priority should be on  the organizations weld  process controls  – best weld practice expertise. These are subjects that over a thirty year period that I simplified and condensed. My training or self teaching resources are available for TIP TIG – Advanced AC-DC TIG – Robot & Manual MIG – Gas Shielded Flux Cored.  If you can give any of these subjects 15 – 20 hours of your time, and pay the cost of a good dinner for four, become an expert.  It’s here.


TIP TIG IS A SIMPLE, NO
NONSENSE  PROCESS THAT IN MINUTES PROVIDES EASY TO PROVE NUMEROUS WELD CLAIMS: As mentioned, t
he TIP TIG patent is built around a mechanical action on the continuous fed wire feed, and  remarkably in an age of electronics,  no electronics are required to attain the numerous weld benefits. With the TIP TIG process, it’s easy in a few minutes demo, to instantly view and measure the substantial weld shop quality and productivity benefits, and  also view the application evidence as revealed at this site, and around the globe with numerous YOUTube videos.


70 YEARS OF REGULAR TIG LIMITATIONS.

Traditional DCEN TIG has rarely been suited as manual, semi-automated process, or a fully automated TIG arc weld process.  Also the automated Hot Wire TIG process is not considered  practical as a Manual TIG weld process.

In contrast, the TIP TIG process is both a manual, semi-automated arc weld process, and  an easy to use fully Automated arc weld process. 

Question.  So why did the regular, 70 year old  DCEN TIG process never make it as a manual Semi-Automated TIG process?

Two restrictions to the manual GTAW process.
[1] The lack of ability to feed small diameter wire typically above 
approx, one pound / hr,
[2] Arc length sensitivity.  

A prime issue with both the traditional manual DCEN TIG and automated DCEN Hot Wire TIG process, is that they are both Arc Length  Sensitive,  (more on this subject below).

Arc length sensitivity. TIP TIG reduces the arc length sensitivity through; 
[] the use of small diameter wires and the increased deposition rates,
[] TIP TIG and more wire delivered enables increased weld current capability that results in larger plasma and fluid weld surface area.
[] TIP TIG’s consistent weld wire placement to sweet spot at the outer periphery of the plasma, takes less energy from the weld, and enables more of the plasma heat to react on the surface of the weld pool. 
[] TIP TIG’s agitation of the weld wire assists in the metal droplet transfer and also results in a slight agitation of the fluid pool that slightly slows down the weld solidification, that helps with both arc length sensitivity and with weld fusion.

The above unique TIP TIG arc plasma attributes combine to allow for higher arc energy, slower weld pool solidification and enable improved electron transfer stability
. Benefits that enable the TIP TIG process to provide higher weld deposition, reduced arc length sensitivity and allows TIP TIG to be either a manual semi-automated or fully automated TIG process
 
Please note:  All of the TIP TIG info. at this site and in my other blogs are my own original thoughts on the TIP TIG process. This copyright protected information is not printed elsewhere. If you want to use it, please at least require my permission

So with that 70 year old DCEN TIG process you may still be using in 2019, arc Length Sensitivity and  dramatic weld deposition restriction are the prime reasons your TIG process is not  suited as a semi-automated arc weld process.  And arc length sensitivity is also a prime reason why the Hot Wire TIG process is not suited to most manual TIG applications.

DCEN TIG Arc length sensitivity is one reason why the automated  Hot Wire DCEN TIG process often requires costly, Automated Arc Length Control, (ALC) equipment. However as  you see below, Arc Length Control equipment is not a requirement with most Automated or robot TIP TIG welds.


Below, TIP TIG attached to low cost automated carriage. These 
multi-pass stainless TIP TIG welds are being made without the usual HW TIG “arc length sensitivity concerns”.

No matter what the weld application size or thickness, if you want the highest possible manual or in this case automated weld quality, get out a rotating table or utilize a robot or  carriage and track as above. In contrast to pulsed MIG which is often used on welds like this, you will produce welds that will not require weld rework, welds without spatter, welds without  fusion, welds without porosity and welds without fume concerns.

 Regular DCEN TIG.

REGULAR DCEN TIG.. Note how approx.  50% of the TIG arc plasma energy  is required  to melt the large wire. This is plasma energy that’s  not being used on the weld surface as it is with TIP TIG.

 

WITH DCEN TIG THIS IS THE WAY IT WAS AND STILL IS.  Compare above,  the traditional 70 year old DCEN TIP TIG arc, with below, the TIP TIG arc. Note to melt that large TIG wire, 1/16 to 1/8 is typical, the TIG wire placement to the center of the TIG plasma energy is important, and this wire placement absorbs much of the TIG arc plasma, so your TIG welder pulls the wire out of the pool and then pushes it in again. This requires skills, reduces the  plasma / weld energy potential and also limits TIG weld deposition rate capability. 


I HOPE YOU ARE NOW AWARE THAT WHERE & HOW THE TIG WIRE MELTS IS IMPORTANT.
For those like myself that love to look at what goes on in the depths of any arc plasma, and examine in detail the transfer of the weld metal, note in this video how in contrast to the manual DCEN TIG weld below, how the DCEN TIP TIG, rapid fed wire melts and forms droplets at the TIP TIG outer plasma periphery. This ensures that minimum plasma energy is being derived from the TIP TIG weld surface.

Question: If the use of large TIG weld wires soak up much of the TIG arc plasma energy, why not use smaller diameter wires like 0.035 or 0.045, (1 – 1.2mm) for the manual DCEN TIG welds?

Answer. An average weld deposition rate with DCEN TIG weld is a sad one pound an hour or less. So instead of using that large 3/32 steel or stainless wire you decide to try and feed an 0.035 MIG wire into the TIG weld pool. To attain one pound an hour with an 0.035 steel wire would require that the manual TIG welder feeds  that wire around 70 inches / per-min. (my finger cramp at the thought). More on this subject below.

Note also that the patented TIP TIG wire agitation enables the small formed weld drops on the wire tip to rapidly detach and transfer into the fluid weld area. Without that unique wire agitation the drops may be slow to detach and the wire could run into the weld pool. 

OPTIMUM WELD FUSION AND LEAST POROSITY IS SOMETHING THAT YOU WOULD THINK MOST WELD SHOPS SHOULD HAVE A KEEN INTEREST IN.

Costly NDT is utilized on most TIG and MIG welds to primarily reveal lack of weld fusion and excess weld porosity. In contrast to DCEN TIG welds, or from any available MIG spray or pulsed weld, the higher TIP TIG weld pool energy generated with any all position TIP TIG welds, should  enable the best possible weld fusion potential and always the lowest weld porosity formation potential.

TIP TIG FEATURE. Apart from the highest weld quality potential TIP TIG enables the lowest possible weld heat input.

Please note also when comparing TIP TIG with Pulsed MIG, that the  TIP TIG weld not only provides much greater arc temperatures. The TIP TIG weld is also protected by an inert gas,  so no MIG CO2 or O2 reactions that influence weld porosity. And also in contrast to Reverse Polarity Pulsed MIG, the electrode negative (EN) polarity with TIP TIG contributes to the lowest possible weld heat input which enables extraordinary weld and  part metallurgical benefits as discussed below. 

TIP TIG FEATURE..In contrast to DCEN TIG, typically 30 to 60% more of the TIG arc plasma is directed at the weld pool. 


For this pipe root TIP TIG still uses same  technique as TIG,
however with fillet welds TIP TIG uses techniques similar to MIG welds. 


QUESTION:  Remind me again, w
hat else increases TIP TIG  weld energy capability?

ANSWER. In contrast to DCEN TIG, the constant fed, small  diameter weld wire capability with  TIP TIG typically will enable a 100 to 400% increase in TIG weld deposition rate capability. The increased TIP TIG weld deposition enables both higher weld current and higher weld speed capability. That faster TIP TIG weld speed potential combined with DCEN polarity enables extraordinary TIP TIG weld and part  metallurgical results, properties  that have never been attained in the weld industry.

My next blog will be on TIP TIG welding TITANIUM. You will see why in 2018, the  TIP TIG  process is the only global Arc weld process that can weld many titanium parts, (meeting aerospace and Nuclear weld standards) without the use of a Gas Trailing Shield.

As alloys are extremely relevant for most global weld shops,  and those alloys mostly attain their properties through heat treatment, why would any weld shop ignore an easy to use process such as TIP TIG that always enables both the highest weld quality potential with the lowest possible weld joules.

THIS TIP TIG WELD IS ACHIEVING SOMETHING THAT NO OTHER  MANUAL DCEN TIG OR  REVERSE POLARITY MIG WELD CAN COMPETE WITH.

Most weld shops typically have experienced weld equipment that’s been loaded with useless electronic bells and whistles, and for decades I have written books on this subject and documented the details in my web site www.weldreality.com. In 2018 after a saturation of the useless electronics we have both process apathy and also Rip Van Winkle engineers and managers that seem to be stuck in a 1960s weld shop time warp. I come across these engineers too frequently in the high tech Aerospace, Defence, Power, Oil and Medical industries. I would request that its about time these engineers  wake up, and for their  companies sake, step up to the plate, take PROCESS OWNERSHIP  and create the CHANGES necessary that can  enable dramatic weld quality and cost benefits for their  companies.  


Words on weld process and consumable differences are often cheap and not based on weld reality. I did the following  UNTOUCHED fillet weld. My question is a simple one.  Are  the  welders in your organization producing untouched fillet welds that look like below?

DON’T TRY TO DUPLICATE THIS UNTOUCHED TIP TIG WELD IN YOUR WELD SHOP. Please note, with my 5/16, single pass, manual fillet weld, the color and small HAZ that can only result from a weld that was produced with low weld heat input. Also note this weld surface and tie-in that indicate high weld fluidity. TIP TIG welds also do not require the weld starts and stops that any DCEN TIG weld would require. Please be aware that a TIP TIG  weld macro should if made correctly reveal a superior weld fusion profile than any DCEN TIG or any Pulsed MIG weld. Of course, TIP TIG will always have lowest weld distortion and porosity potential. 



PIPE OR PLATE, STEEL OR ALLOYS.

With TIP TIG welds you simply don’t expect those costly weld defects


For the few weld shop manager that seem to actually give a dam about looking for real world methods to reduce their weld shop costs,  TIP TIG will reduce DCEN TIG weld labor and the weld gas costs typically in the range of 200 – 400%.

WITH MANY CODE QUALITY WELDS WELD SHOPS WILL USE TIG FOR THE ROOT AND MIG – FCAW – SAW FOR FILL PASSES…

Why would any weld shop in 2019 bother with multi-processes for their welds. Why would you want to weld using two processes, different equipment, different weld consumables, different weld procedures, different welder qualification skills, different weld procedures and still end  up with welds that require weld rework.

With TIP TIG no matter what the weld application size or the thickness, is TIP TIG is a cost effective weld process for all Root & Fill passes that require code quality welds. And if my TIP TIG weld settings and best TIP weld practices are used, no weld rework. This program is the self teaching / training program section of  www.weldreality.com.

In contrast to pulsed MIG, the TIP TIG lightweight torch enables it’s ceramic nozzle to make contact with the grounded work, this acts as a guide, (would typically bad MIG practice with MIG nozzle). Also  in contrast to TIG, no foot control required. Its also obvious from all the videos and photos at this site that TIP TIG enables the lowest possible weld fumes, so welding stainless and nickel alloys less concern for those Hexavalent Chrome Cr3 carcinogens that can cause cancer.  


IT’S HARD FOR ME TO UNDERSTAND WHY ANY WELD SHOP WOULD BE HAPPY WITH A PROCESS SUCH AS TIG THAT PRODUCES THE SLOWEST ARC WELD SPEEDS AND REQUIRES THE HIGHEST ARC WELDER SKILLS.  The TIP TIG welder does not have to feed a wire or work a foot control. The TIP TIG welder  can use one or two hands on the lightweight TIP TIG torch. And it may not be important to your business but most none TIG welders can if using my self teaching / training resources, learn the TIP TIG process in a week and be able  to pass any all position code welder qualification requirements.


I SUPPOSE THESE ARE MINOR DETAILS FOR MANY BUT I THINK THEY ARE IMPORTANT, ITS NICE TO HAVE NO WELD  DISTORTION OR WELD FUME CONCERNS. TIP TIG with DCEN and faster TIG weld speeds, thanks to the EN polarity and faster weld speed TIP TIG in contrast to TIG and pulsed MIG, is a process that will always provides the least possible weld distortion, the cleanest possible welds and the lowest weld fumes.


The world’s largest Nuclear Waste Site instantly attained great weld benefits from the TIP TIG process.

 As Bechtel at the Hanford Nuclear waste treatment plant found out, when the highest weld quality, short weld times and reduced welder skills were beneficial, they turned to TIP TIG.  Now if only the rest of Bechtel management and engineers could figure out the daily weld quality – costs benefits that there organization could attain with the elimination of TIG and Hot Wire TIG and the adoption of TIP TIG.

SOME PEOPLE IN THE WELD INDUSTRY MIGHT THINK THIS IS IMPORTANT…TIP TIG, dramatically lowers TIG welder skills, lowers weld costs, reduces weld procedures, does not require multi-weld processes and expect no weld rework, spatter or weld fume concerns.

So its 2018, put the earphones, turn off that bloody Fox News and pipe in some cool jazz. Assume the position on the pipe and relax. No feeding a wire. No foot control, provide those all position code quality pipe welds without worrying about weld rework. Now do something that might even make the weld shop manager smile. Produce the pipe welds at 300 to 400% faster than you used to do with TIG. Also take note with TIP TIG, you do the root and all the pipe fill passes with two simple weld settings. Pipe welding has never been this simple. And for more than a decade, the fact you may have never  seen it, has been  my frustrating weld reality.


LABOR & GAS COSTS, AND NO GRINDING WHEELS REQUIRED. In contrast to traditional DCEN TIG, with the greater TIP TIG weld deposition rates and the increased arc on times, the TIP TIG weld labor costs and weld gas costs should typically be 25 – 30% of  a company’s present DCEN TIG labor & consumable costs.

WELDS WITHOUT FUSION OR POROSITY CONCERNS. In contrast to DCEN TIG, the TIP TIG process with it’s ability to provide more weld energy from increased weld current enabled from increased weld deposition, more uniform wire melt from the weld wire consistently fed to the plasma sweet spot,  and that unique wire and weld pool agitation, the results should always provide superior weld quality.

For those “Why Change Characters”. Take a look at the pipe root video below. Why is someone not getting hand cramps from feeding the TIG weld wire?

How come with TIP TIG they don’t need amp foot controls?

 

Click on the TIP TIG manual pipe root video below, note the continuous weld fluidity, the weld purity and energy in the most critical part of any pipe weld. No defects in a TIP TIG root.

ONE PROCESS IS NOW PRACTICAL FOR ALL WELDS...


With pipe welds, a weld shop often will use two arc weld processes for the pipe joints. They may use TIG for the root and and flux cored or pulsed MIG for the fill passes.  Irrespective of the welder’s skills, with both MIG and flux cored, there will often be process influenced weld fusion – weld slag – weld porosity issues, and therefore the weld shop will typically will anticipate weld rework. Or the weld shop may may simply  do the root and fill passes completely with the super slow, time consuming TIG process. In contrast, using two TIP TIG weld settings for any pipe welds, the weld shop should  anticipate with X-Ray evaluation, zero weld rework. Its this simple, the TIP TIG process will be highly cost  effective for any pipe or plate  fill passes with any pipe / plate wall thickness, or any pipe diameter.

TIG CONCERNS. Due to the very low traditional DCEN TIG deposition rates which effect current content and plasma energy and also the TIG arc length sensitivity,  TIG has often been a poor choice for automated weld applications which require filler metal and dont have automated arc length controls. In contrast  TIP TIG provides much higher weld deposition rates enabling 200 to 400% + weld speeds and TIP TIG does not have either the manual or automated  arc length sensitivity that TIG has. With TIP TIG get the benefits from manual welds then simply attache TIP TIG to a  Bug-O,  a Turntable, or a Robot, and be ready be amazed at the weld results.


Manual or automated, TIP TIG  does
not require costly weld automation equipment. 

Attach that TIP TIG torch to a mechanized carriage and produce those stainless, Inconel or Duplex tank welds. No weld defects, no weld distortion issues & no weld chrome fume concerns. What about TIP TIG & a robot?


ABB, one of the world’s largest Robot Mfg, companies used to shy away from robot applications that required the arc length sensitive, slow moving TIG process and then Ed introduced ABB USA  to TIP TIG.

I used to be the US robot weld manager for ABB robots. Around 2010 after I left ABB, I went back to their head office to tell their engineers about the unique robot opportunities with TIP TIG which I had acquired the rights to North America. I went over the TIP TIG feature benefits of not only a great manual weld process but how it was also ideally suited to numerous  robot applications, especially with defence, aerospace, power and oil – gas applications. They were impressed, but like many young weld engineers,  lacked the weld application expertise and perhaps vision to buy into marrying TIP TIG To their robots. Approx. eight years later around  2017 –   some ABB engineer or manager woke up and finally figured that TIP TIG should be their TIG process of choice for those applications that required the weld quality, metallurgy and other  benefits  provided by TIP TIG.


SOMETIMES THE MANAGERS  WILL  LAMENT… ANOTHER BIG JOB COMING UP, 
AND WE CAN’T FIND SKILLED TIG WELDERS?

TIP TIG dramatically reduces TIG welder skills. A TIG welder needs a day and someone who has never TIG welded can in a week pass most all position code welder qualification tests. Lets face it, the welder does not have to know when and how to feed the weld wire. The weld wire is always delivered to the arc plasma sweet spot. The continuous fed wire drives the welders speed.  A foot control is not necessary.  Weld start and stop data is automatic and optimum.  In contrast to any all position TIG, Pulsed MIG or flux cored welds, a five minute demo would show the weld shop how easy it is to use the TIP TIG process. 

THIS HAS NEVER BEFORE BEEN SAID ABOUT ANY OTHER ARC WELD PROCESS BUT CAN BE PROVEN IN MINUTES.  Think about the billions of dollars annually spent around the world on the costs associated with weld rework. If used correctly, TIP TIG is a weld process in which you should expect  ZERO weld defects, and with the highest weld quality with lowest weld heat you should also always expect the best mechanical and corrosion properties with all steels / alloy steels and alloy weld applications. 

By the way, with my Self Teach – Training Materials, it would take you approx. 20 hours to become a weld process control – best weld practice expert in one of the following. Manual / Robot MIG, Flux Cored,   Advanced AC/DC TIG Aluminum, and also with the DCEN TIP TIG process. Click here to take a look at the programs.

The low deposition,  regular TIG was often poorly suited for large size and thick applications. This has changed with TIP TIG. Applications big or small, all position TIP TIG welds are simple and cost effective, and of course it’s much more profitable for any weld shop when weld defects are not revealed. It’s also nice to guide that light torch with two hands. Also   not get leg cramps from a foot control. Additional weld benefits you  have to deal with weld cleaning, weld spatter and weld fumes as we did with pulsed MIG or gas shielded flux cored.

AGAIN, HOW IMPORTANT IS IT WITH THE HIGHEST WELD QUALITY POTENTIAL TOO ENABLE THE LOWEST POSSIBLE WELD JOULES THAT IS  ENABLED THROUGH THE INCREASED TIP TIG WELD SPEEDS AND THE EN POLARITY? 

Apart from the obvious mechanical and corrosion property weld benefits from the lowest possible arc weld heat , TIP TIG  if required enables the widest possible weld heat range. This fact combined   always with the highest possible weld quality potential, should always enable the best possible metallurgical properties. Think about those clad applications in which you can now do one layer as you are attaining the lowest possible weld dilution. TIP TIG also will provide the best possible impact properties from the smallest weld HAZ.


TIP TIG IS THE ONLY ARC WELD PROCESS THAT ENABLES THE LOWEST WELD STRESSES. THE HIGHEST POSSIBLE IMPACT PROPERTIES FROM DEFECT FREE WELDS WITH  SMALLEST POSSIBLE HAZ. AS A BONUS THROW IN THE  THE LOWEST POTENTIAL FOR WELD CRACKS, AND DISTORTION.

REDUCED PRE-HEAT AND INTERPASS. By the way, when you dramatically  reduce weld heat input, it’s also likely  you can eliminate interpass weld temp and reduce or eliminate preheat and post heat. Of course you could ignore these game changing weld benefits as most have done and  continue to arc weld the way it’s been done since TIG was first introduced in the 1940s.

WELD SHOP DECISION MAKERS NEED TO BE AWARE THAT TIP TIG IS MUCH MORE THAN A ONE OFF WELD  PROCESS SOLUTION FOR A PROBLEM WELD…..  

Many of the global TIP TIG sellers while exited by their sales growth will also be aware that in many instances, their TIG TIG units are purchased by weld shop as a one off weld process  SOLUTION. For example, the weld weld shop may have a weld problem with a specific alloy like Titanium, Duplex or Hastelloy, or have a difficult  crack sensitive weld application that could result in excess weld labor costs or costly weld rework. Of course, TIP TIG with it’s highest weld quality and lowest weld heat potential should provide the best possible weld SOLUTION.  Meanwhile, in the same weld shop that purchased the TIP TIG unit, the primary weld processes used in the weld shop for the code quality welds continues to be traditional What most global weld shops often don’t realize, especially with manual or automated, all position, code quality welds on steels, alloy steels & high strength steels on 16 gage to any thickness, is that TIP TIG is superior to all arc weld processes and can  provide numerous, unique, game changing  weld quality and weld cost benefits.

2018, TIP TIG HAS BEEN AVAILABLE FOR MORE THAN A DECADE

[] CONSIDER TIP TIG WHEN QUALITY WELDS THAT WON’T REQUIRE WELD REWORK WOULD BE VALUED.

[] CONSIDER TIP TIG WHEN THE BEST WELD & PART METALLURGICAL PROPERTIES ARE REQUIRED.

[] CONSIDER TIP TIG WHEN THE LOWEST WELD DISTORTION HELPS.

[] CONSIDER TIP TIG IF  YOU ARE USING TWO WELD PROCESSES, FOR EXAMPLE ONE FOR A ROOT AND ONE FOR FILL.

[] CONSIDER TIP TIG FOR ALL POSITION WELDS, AS THAT TIP TIG PROCESS WILL REQUIRE LESS WELDER SKILLS.

[] CONSIDER TIP TIG IF YOU WANT THE CLEANEST WELDS WITH THE LOWEST POSSIBLE WELD FUMES.

TIG weld costs and lack of  weld rework costs:  TIG weld costs are rare discussion with a process that often produces welds at the speed of a turtle. Its more likely the weld shop is concerned about not having enough skilled TIG welders. So let’s take a look at a process that dramatically lowers the weld skills and speeds up the weld speeds.

Two weld shops are about to bid on a new five years code quality weld contract and need compete with each other. 

SHOP ONE TOOK THE TIG APPROACH: 

To get a welding project contract, shop one figures it needs to hire 10 DCEN TIG welders. The welders will mostly be welding on high strength steels and alloy steel, ASME code applications. Most of the parts TIG welded will be  3 to 25 mm thick. The project will last at least 5 years. The basic labor and power source budget for the shop one.  Weld labor first year. 10 welders x $65.000 = $650.000/yr. Plus 10 Inverter DCEN TIG power sources,  $7000 = $70,000. SHOP ONE first year labor costs plus weld equip.= $720,000. Remaining 4 years of TIG labor costs 4 x $650K =  $2.6 million, plus year one costs of $720,000 for a total  5 year weld labor / equip. costs… $3,320.000.

SHOP TWO TOOK THE TIP TIG APPROACH:

This shop also is looking to  bid on the above contact. These guys had progressive weld management  that selected the TIP TIG  process.  With TIP TIG the weld shop can expect a minimum  300% increase in the TIG weld production attained each hour. Shop TWO was going to bid on the job with three  welders for the TIP TIG units. As much less welder skills are required with TIP TIG, it typically takes a few days to learn. The TIP TIG equipment costs were approx. $26,000 each = x 3 = $78,000.

Shop two employs 3 TIP TIG welders at an annual labor costs per-year of  $195,000 + $78.000 equip. costs, = first year weld costs of $273,000. Shop two, 4 year labor costs x $195,000 = $780,000,  plus year one costs $273,000. Shop two five year labor / equip costs $1,053.000.

Note, zero weld rework can be anticipated with TIP TIG, and also an approx. 300%  reduction in the annual argon gas costs. I am aware of many defence, aerospace, power, oil and other high tech companies that employ in their global facilities hundreds of TIG welders each year, thanks to their poor management and engineering decision they don’t seem to mind throwing  millions of dollars away every year.

CONFUSION BETWEEN HOT WIRE TIG & TIP TIG.

In the last decade while  providing weld solutions for numerous plants, I found out that when discussing the merits of the unique TIP TIG weld process, that there was much confusion between  the strictly Automated Hot  & Cold Wire  GTAW DCEN TIG  processes, and the Manual – Automated TIP TIG process.

A typical Hot Wire clad application on left. An often poorly understood feature of many automated, “all position” HW pipe welds is the limitations that occur with the HW weld wire most often having to be placed behind the arc. If you are a right handed manual TIG welder pretend you have a semi-automated TIG torch that feeds the continuous fed weld wire at the rear of the arc, poor arc & weld visibility and weld control would immediately be a concern. In contrast for manual and automated GTAW the TIP TIG process feed its weld wire  in the arc front.

TYPICAL HOT WIRE WELD BELOW. NOTICE WHERE WELD WIRE IS FED & THE SENSITIVE OF THE WIRE TO WELD CONTACT.  

The continuous HW weld wires are often fed so the wire is making contact with the weld pool surface behind the tungsten. This wire feed is highly sensitive to  and HW wire feed rate variations, weld pool fluidity changes, and especially sensitive to  any ARC LENGTH variations that effect the  plasma profile, plasma intensity and weld energy. The sensitivity of the automated HW process is further enhanced with low to moderate HW weld current applications which limit the arc plasma size and intensity. The above limitations of some of the reason the HW process cannot perform as  manual semi-automated HW TIG weld process.


IN CONTRAST TO HOT WIRE ABOVE TAKE A LOOK AT TIP TIG.

IN CONTRAST TO MANUAL TIG AND THE INCONSISTENT WIRE FEED, TIP TIG IS A PROCESS THAT AGITATES THE CONTINUOUS FED WIRE AT THE PERIPHERY OF THE ARC PLASMA . THAT CONTROLLED  WIRE FEED RATE CONTROLS THE WELD MELT UNIFORMITY AND DRIVES THE WELD TRAVEL RATES.


Note: For extensive  reasons why the  Hot Wire TIG process cannot compete with the TIP TIG process, visit my Hot Wire TIG blog.

If all that was needed to make DCEN TIG into a Semi-Automated TIG process was  attache a  MIG wire feeder and liner and contact tip to a  TIG torch so you could feed the wire to the TIG pool. This is what  Cold Wire TIG is, then  you would have no need for Hot Wire TIG or the TIP TIG process. With that Cold Wire feed process as soon as the welder  walks the Cold Wire torch ceramic cup in a groove weld, especially when using  low to moderate TIG amps, the welder would immediately be aware of  what  arc length sensitivity means. To make the Cold Wire TIG work, the welder would  have feed a small diameter 0.023 to 0.035 Cold Wire feed at a CW weld deposition rate that is in reality. not providing any greater weld deposition rate above what can be attained with any   manual DCEN TIG welder.

 A SUBJECT RARELY DISCUSSED IS THE DCEN TIG WELD DEPOSITION RATES. Let’s say that manual TIG welder is pipe welding  and using a 3/32 steel or stainless wire for the pipe vertical up fill passes. The welder typically would feed and be depositing around 8 to 10 inch/min of the 3/32 wire length each minute. At  8 inch/min of 3/32 thats  approx.  1 lb/hr. 

With the manual DCEN TIG deposition of 1 lb/hr and an arc on time of 20 min/hr =  YAWN those TIG  welders are typically depositing  on average approx. 0.4 lb/hr.

In contrast to a manual TIG welder, a TIP TIG welder putting in the vertical up  fill passes on any steel or alloy steel pipe would average with an 0.035 MIG reel, about 180 inch/min of wire or approx 2.5 /lb/hr. As TIP TIG is a Semi-automated or fully Automated TIG weld process, it would of course when used manually also increase the TIG arc on time dramatically.  With the manual TIG pipe welder depositing 0.4 lb/hr, with a manual  TIP TIG pipe weld arc on time of  say 40  min/hr =  the TIP TIG welders would  typically depositing  on average  1.6  lb/hr.  The TIP TIG welder is depositing 300% more TIG weld each hour.

You don’t have to be a rocket scientist, (or do you) to figure out that this simple weld cost comparison between a manual TIP TIG and manual TIG welder would have has major weld cost ramifications for any weld shop who employs managers, engineers and supervisors  that will  wake up and smell the long overdue weld evolution of TIG. 

PLEASE EXAMINE THE WIRE SIZE USED, AND THE WIRE FEED & DEPOSITION RATES: Often on thin wall applications when using HW or Cold Wire on all position pipe welds, take a look at the wire feed rates being  achieved. For example that  automated 0.023 steel wire thats running at approx. 140 inch/min sounds much more cost effective than the manual TIG welder feeding their 3/32 wire at 8 inch/min.  That 140 inch of 0.023 wire =  1 pound/hr.  A MIG wire reel 0.030 steel wire running at approx. 80  inch/min =  1 pound/hr. Apart from not be suited to most manual TIG welders with HW – CW welds, weld deposition rate restrictions is a major issues with low to moderate amp welds.


How easy the welders life becomes with TIP TIG:

2018 TIP TIG….In contrast to your manual DCEN TIG welder,  the above TIP TIG welder is working less hard, they require less welder skills, will be providing higher weld quality, superior weld metallurgy, and each hour will be depositing approx 200 – 300% more weld per/hour  than any of your  TIG pipe welders.  Possibly these are not enough weld  quality or weld cost reduction incentives to get  the high tech, front office, Defence, Energy,  Aerospace and Oil industry managers and engineers exited.


So I now want to point out more of the weld limitations with the  
approx. 70 year, little changed,  DCEN GTAW (TIG)  process.

For decades, when high arc weld quality on steels and alloys was required, the most common process of choice was and still is in 2018, considered the DCEN TIG process. For automated DCEN TIG welds, the Hot Wire (HW) TIG process would  typically be utilized as shown below.

 

High Amp Clad welds have been a common HW application.

2018.. HOT WIRE TIG: Pipe OD and pipe ID welds are common Clad weld applications  in the Subsea industry that requires the highest weld quality. HW has for decades and still in 2018 being purchased by weld shops who don’t know what TIP TIG is. 


WHILE  THE PURPOSE OF THIS BLOG IS TO PROVIDE EXTENSIVE INFO. ON MANUAL DCEN TIG, VERSUS THE MANUAL DCEN TIP TIG PROCESS, I ALSO WANTED  REDUCE THE PROCESS CONFUSION THAT SURROUNDS TIP TIG VERSUS HOT WIRE TIG. THE DATA IS IN THE TIP VERSUS HW BLOG.

As you become more aware of  the manual DCEN TIG and the automated DCEN. Hot Wire TIG weld process limitations as revealed in this blog,  you will become more aware of why these processes simply cannot compete with  DCEN. TIP TIG.  

New traditional TIG and so called sophisticated Inverter TIG equipment. Lets also not forget the fancy work gear. However in contrast to  a 60 year old DCEN TIG power source, no real world DCEN TIG weld quality or productivity weld benefits are being attained from the changes provided in this or in any new TIG equipment. 

THE MANY ACHILLES HEELS OF THE DCEN TIG PROCESS. 

Since the 1940s, when Code Quality welds on High Strength Steels, Alloy steels and Alloy welds were required, DCEN TIG was often the weld process of choice. However weld shops should never forget that those high strength steels, alloy steels and alloys attain their Mechanical or Corrosion Properties through Heat Treatment.  And  both the manual DCEN TIG and Automated Hot Wire DCEN TIG slow weld speeds, especially on  parts over 2 mm thick, can create high weld joules and part heat concerns.

Those typical DCEN TIG low weld deposition rates impact the low weld speeds and the weld times per part, the weld labor and TIG weld gas costs. The slow weld speeds also influence  the weld and part heat  influencing both distortion and the metallurgical properties. The DCEN TIG weld heat may  also  be influencing the required weld preheat, interpass and post heat temperature requirements. Also  lets not forget the high TIG weld temperature influence the induced stresses that can influence both weld and part cracks.


NO RESPECTABLE WELD ENGINEER, MANAGER OR SUPERVISOR SHOULD WANT TO HEAR IN THEIR WELD SHOP. WHY CHANGE?

It’s understandable that at most weld shops where every lunchtime the welders will usually sit at the same seat in their lunch area, would therefore be reluctant for a major weld process change, especially when the have been using a seven decade old DCEN TIG process. 

When that weld shop daily uses TIG, and has not had an alternative  weld process choice for decades, it’s understandable that anyone in the weld shop would give much consideration to the negative attributes of their DCEN TIG process. 

TO BE AWARE OF THE POSITIVE ATTRIBUTES OF A NEW  PROCESS, ONE HAS TO FIRST BE AWARE OF THE NEGATIVE ATTRIBUTES OF THE PROCESS BEING UTILIZED.


To show the DCEN manual TIP TIG weld benefits, I have to also point out what has been wrong for seven decades with the traditional DCEN TIG process. 

THE INFLUENCE OF TIG WELD SKILLS: In a time of global shortages of skilled TIG welders, a prime negative attribute of DCEN TIG, is that in contrast to  all the other arc weld processes used for manual welds,  DCEN TIG has required the highest Manual Welder SKILLS For decades, this has dramatically impacted  production times, hourly weld labor rates and also the weld quality attained.

SKILLS  INFLUENCE ON WELD QUALITY? When a process such as TIG is difficult to learn and use, and lets say five manual TIG welders are welding the same, all position, code quality parts, you will see distinct weld differences on each parts. Its this simple, skills will influence the weld quality attained, and DCEN TIG is an arc  weld process that has always required the highest welder skills. 

Simple to use TIP TIG. No need to feed wire. No foot control. No spatter.  No fumes. No weld rework. Happy bosses. Put the ear plugs in, a listen to some good  music, and don’t forget to tell the wife you have had another hard day in the weld shop.


SINCE AROUND 2009 IN NORTH AMERICA,  WITH TIP TIG YOU WERE NOT ONLY GETTING  THE HIGHEST POSSIBLE WELD & PART QUALITY, YOUR WELD SHOP WOULD HAVE REDUCED IT’S MANUAL TIG WELD COSTS BY AT LEAST 70%. ALSO THE WELD SHOP WOULD HAVE BEEN USING A PROCESS THAT REQUIRED THE LOWEST “ALL POSITION WELDER  SKILLS. I HOPE YOU DON’T WAIT ANOTHER DECADE BEFORE YOUR WELD SHOP AWAKES TO WELD REALITY.

IN CONTRAST TO MANUAL TIG WITH IT’S INCONSISTENT WIRE FEED, TIP TIG IS A PROCESS THAT AGITATES THE CONTINUOUS FED WIRE TO THE ARC PLASMA SWEET SPOT. THAT CONTROLLED  WIRE FEED RATE THAT SHAKES THE WELD DROPS INTO THE PLASMA AND WELD, ENABLES CONTROL OF  THE WELD MELT UNIFORMITY AND DRIVES THE WELD TRAVEL RATES.


HOT WIRE CURRENT IS PART OF THE TIP TIG PROCESS.. Like Hot Wire TIG, a part of the TIP TIG process also utilizes HOT WIRE current 80 TO 100 amps is norm to preheat the constant wire fed TIP TIG wire into the arc. 


HOWEVER, PREHEATING THE WIRE FED INTO A TIG ARC AS WE HAVE SEEN WITH HOT WIRE TIG,  STILL DOES NOT ALLOW THE HW PROCESS TO BE USED FOR MANUAL WELDS. MOST HW APPLICATIONS WILL NEED AUTOMATED ARC LENGTH CONTROL. 

With DCEN TIG, a portion of the plasma is required to melt the large wire, of leaving a small fluid, fast freeze area highly influenced by arc length changes that occur with torch angle or height changes.


WITH HW TIG AUTOMATION, ARC LENGTH SENSITIVITY IMPROVEMENTS ARE SMALL AND THE HW IMPROVEMENTS DO NOT OVERCOME MANY OF THE MANUAL DCEN TIG SHORT COMINGS. HW  IS RESTRICTED TO WELD AUTOMATION. 

In contrast to Hot Wire TIG, the TIP TIG  process requires both the HW anps, and most important an agitated weld wire which completely changes the DCEN TIG weld dynamics enabling TIP TIG to be utilized as  both  an easy to use  Manual Semi-Automated and  fully Automated DCEN TIG weld process.

THE GREATER THE WELD DEPOSITION RATES ALLOWED THE GREATER THE WELD AMPS THAT CAN BE USED.

In contrast to regular DCEN TIG and Hot Wire TIG, the TIP TIG process  provides major increase in the weld deposition rates, far greater weld quality, less part heat that enables  superior metallurgical properties,  less distortion, less stresses, and  the least possible weld fume. All  lead to dramatic  weld quality, production and weld cost benefits. 

TIP TIG requires no electronic bells and whistles, it’s prime feature is a unique, patented,  simple but highly effective mechanical change to the continuous weld wire feed delivery system to a TIG arc.  This invention  enables TIP TIG to truly be called the evolution of the TIG.


More on TIG and Hot Wire TIG versus TIP TIG.

2018:  As the DCEN TIG process hardly changed in seven decades, it’s understandable that there has been little focus on what the DCEN TIG process does not do well

Around 2009, I first saw  the TIP TIG process at a small distributor location in  bonny Scotland. The distributor was run by my now good friend Darren Mathieson. After evaluating the  TIP TIG process capability and being well aware of the traditional DCEN TIG weld issues, it took me about 15 minutes to get very excited about this  new TIP TIG process and on its future impact on global weld applications.

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This is what most weld shops that use TIG in 2018 dont have.  With TIP TIG, unique manual and automated TIG weld wire agitation.  TIP TIG, unique manual wire to sweet spot arc placement. TIP TIG, unique manual TIG arc plasma energy distribution over the weld pool. TIP TIG, unique TIG higher deposition rates attained. TIP TIG, unique faster TIG weld speeds being attained. TIP TIG, unique higer manual weld quality than TIG and lower weld joules being attained.


So what do you do with a unique weld process Like TIP TIG, to introduce it to  a country like the USA which in general has an entrenched in the weld shop attitude of “WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT” 

 In 2009 when i found TIP TIG,  I had been involved with arc weld process equipment evaluation for approx. 40 years, I knew how embedded the traditional DCEN TIG  process was especially in the high tech industries such as Nuclear, Aerospace, Defence, Medical, Oil and Gas,  where front office weld ownership, weld process controls and best weld practice were often lacking and few liked change. 

As today I have little to do but think and write, I figured a Weld Process Comparison blog such as this, that also enabled access to my unique Weld Process Control self teaching / training programs on TIP TIG – Advanced AC/DC  TIG – MIG / Pulsed and Flux Cored would be helpful for those few that are beginning to believe in the importance of process ownership and  weld process controls – best weld practices.

Contact  ecraig@weldreality.com.  If you want a TIP TIG, flux cored, MIG or Robot MIG process control workshop, seminar or  training at your organization, give me a call. 828 337 2695. 

Following are some of the Negative or Restrictive attributes  that for seven decades have been part of the  traditional  DCEN TIG process.

Traditional TIG 

Traditional TIG requires TIG welders use skills to dip the large weld wires that typically provide on average approx. 1 lb/hr . Those big TIG wires take heat away from the weld pool.

[] With traditional TIG, oversized weld wires are required, the reason the welder would not want to manually feed a smaller wire such as an 0.035 (1mm), with an 0.035 wire the TIG welder would have to feed that wire at  approx. 70 inch/min,  just to achieve one pound an arc on hour. So instead the TIG welder takes a large weld wire typically 1/16 to 1/8,  and dips that it in and out the the TIG weld puddle, still often depositing approx one pound hour. Note above again, the large TIG wire  and the resulting small rapid freeze TIG weld pool.

[] So that  TIG  small plasma size and the plasma intensity produced  is influenced by the “TIG weld current restrictions that are influenced by the very low weld TIG deposition rates that are typically used. 

Note: With DCEN TIG,  a weld deposition of less than 1.5lb/hr is considered normal. Take a look at another TIG negative, the poor DCEN TIG plasma energy distribution.  Approx. half the TIG plasma energy is being utilized to melt the large TIG wire tip, while the remaining arc plasma energy is being used to maintain the very small fluid weld area.
That  fast freeze,  small fluid weld area with traditional TIG weld, not only restricts the TIG weld deposition potential, it also  adds to the common TIG arc length sensitivity, (especially noted with automated HOT – COLD Wire TIG welds and robot TIG welds).
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[] Compare plasma energy distribution above and weld wire  location and action with this TIP TIG video. Remember also we have the reduced welder skills as the TIP TIG welder does not have to place the weld wire into the arc. 

[] So with manuala TIG the welder has to coincide the movement of the torch with the The manual manipulation of the TIG torch,  the careful feed of the TIG wire, the sometimes requirement of  a foot amp control, all add to the required TIG welder skills, and these are skills that can influence the weld quality obtained from one  TIG welder to another.

The low DCEN TIG deposition usually 1 to 1.5 lb/hr often require very slow weld speeds. Manual DCEN TIG welder travel rates of  1 – 6 ipm are common on parts >2.5 mm. A major consequence of the very slow TIG weld travel rates is the high weld heat generated and this heat can  create metallurgical, stresses or distortion concerns with the  parts welded.

So what would you like to change with the DCEN TIG process? How about that poor plasma heat distribution that restricts weld deposition rate potential.  In contrast, take note of the TIP TIG plasma energy distribution below.

Would it be a benefit to you or your weld shop to dramatically reduce the TIG welder skills?  For more than a decade, global skilled TIG welders have been in short supply.  As we will discuss  TIP TIG  dramatically reduces TIG welder skills.

 

TIP TIG compensates for the negative attributes that are  discussed here with the traditional manual TIG process, and this also applies to the Automated Hot – Cold Wire TIG processes which have the same negative attributes.

The TIP TIG data in this blog is miniscule to what I provide  in my TIP TIG self teaching / weld process  control – best practice training program. This program provides all the TIP TIG information, the weld data and the best TIP TIG weld practices for any all position manual and automated weld applications.

To get your employees  familiar and comfortable with this important process, this is the resource you need,  click here.

 

With TIP TIG its not as simple as the remarkable  increase in TIG hourly weld production, typically in the 200 to 400% range, The higher TIP TIG weld energy and dramatic increase in DCEN TIP TIG weld speeds,  provides remarkable weld and part property benefits.


EVEN IN WELD SHOPS EVENTUALLY THINGS CHANGE: From 2010, weld shops in North America and around the globe have had access to the easy to use TIP TIG process.

2018;  On steels and alloy steels, compare the DCEN TIP TIG with the  weld benefits attained with traditional DCEN TIG. 

TIP TIG higher weld deposition rates, greater weld current, agitated welds  and the continuous delivery & placement 0f a small diameter weld wire into the arc sweet spot, enables optimum melt and fusion. Also the continuous wire feed for the manual welder helps regulate weld speeds.

  • View below how most of the the TIP TIG plasma energy is on the weld, which increases the weld energy and the weld fluidity, adding to improved weld fusion capability and lower porosity.
  • The greater TIP TIG weld deposition rates also enable higher weld amps to be used and these amps improve the plasma profile and intensity and also add to weld fusion improvements with decreased porosity.
  • That higher TIP TIG deposition means 200 to 400% more TIG weld each hour from welders who require less skills while delivering higher weld quality than TIG. Think about the importance of dramatic labor costs and reduced skills.
  • The increase plasma size and intensity reduces arc length sensitivity making TIP TIG highly suited to all manual and automated applications.
  • Weld pipe? With TIP TIG all you need is one process for the root and fill and two simple TIP TIG weld procedures are all that will be required for most pipe welds made in any weld positions.
  • The increased  in TIP TIG deposition enables much faster weld travel rates that when combined with DCEN polarity enables the lowest possible arc weld joules, which not only provides remarkable metallurgical results, but also the lowest weld stresses, the lowest  distortion and lowest weld oxidation potential, (lowest porosity).
  • TIP TIG enables a dramatic reduction in welder SKILLS. No requirement to feed a weld wire means you can hold the torch with one or two hands. No skills required knowing when to dip the wire into the weld pool. No foot control required and  TIP TIG also always provides fully automated control of  the weld starts & stops.
  • TIP TIG agitates the wire helping release the weld drops it also agitates the weld pool providing many benefits discussed below.

TIP TIG. Most of the plasma energy directed at the weld and wire continuously fed in arc sweet spot. Compare the TIP TIG plasma weld energy distribution against the TIG plasma energy distribution above.

Regular TIG, like TIP TIG also utilizes Electrode Negative (EN) weld polarity. EN polarity is the best arc polarity for weld heat reduction. EN polarity can rapidly dissipate much of the weld heat away from the weld  into the part being welded. However as  regular Manual TIG, and also the Automated, Hot and Cold Wire TIG users are aware, these processes typically provide very low deposition rates that require very low weld travel rates. Manual TIG weld travel rates on parts > 3 mm are often in the 2 to 6 inch/min range.

My  TIP TIG self teach / training program provides the unique TIP TIG weld settings and best weld practices for all global steels and alloy steels weld applications. The program simplifies the TIP TIG process teaching requirements,  and as with all my programs I provide three optimum TIP TIG weld settings that can be applied to the majority of all global steels and alloy steels  applications. As not everyone needs TIP TIG, this training program also includes the  Advanced AC/DCEN TIG  process. After all why purchase more sophisticated inverter TIG  weld equipment technology and then watch your  welders play around with their new power source controls. 

Contact  E. Craig  ecraig@weldreality.com.  If you want a DCEN TIP TIG, Advanced AC TIG, Flux Cored,  robot or manual MIG-Pulsed MIG weld process controls – best weld practice training at your organization, give me a call. 828 337 2695. 

If you want to do it yourself, the best possible TIP TIG, flux cored, manual MIG and Robot MIG Self Teaching / Training process controls & Best Weld Practice resource are here..

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For those that have never seen a perfect untouched weld take a look above. Manual and Automated TIP TIG welds are easy to produce  that consistently meet any all position code weld quality requirements with the lowest possible weld rework requirements and always the best possible weld and part mechanical or corrosion properties. This applies to any steels and alloy steels global  weld applications.

So with regular TIG, while in contrast to electrode we have the amazing weld benefit of  EN polarity that should allow rapid weld heat dissipation from the welds into the parts, unfortunately the very slow TIG weld speeds then generate the typical high weld and part heat input. 

In contrast to regular TIG, the DCEN TIP TIG process through it’s unique patented mechanical wire feeder action, creates  both a weld wire and weld pool agitation, (think of a plucked guitar string).  The agitation of the weld wire enables rapid small droplet transfer from the tip of the continuously fed small diameter tip. The agitated wire droplets also provide a small agitation the weld pool that helps slows down the TIP TIG weld solidification. Slowing the normally rapid TIG weld solidification prolongs the arc electron transfer, reduces the arc length sensitivity and enables more of the TIP TIG wire to be fed into the weld pool.  Increased TIP TIG  wire deposition per-weld,  enables more weld current to be utilized  creating a wider more intense plasma than TIG.

The dramatic changes produced by the  TIP TIG weld  dynamics, enables  greater TIG weld deposition rates which allow for  much faster TIP TIG weld speeds. The typical DCEN  TIP TIG weld speeds on parts > 3 mm are in the range of 8 to 25 inch/min, in contrast to traditional TIG welds being produced at 2 to 5 inch/min. The increased TIP TIG weld travel and  low TIP TIG arc voltage enable dramatic weld joules and part benefits.

TIP TIG ENABLES A UNIQUE ARC WELD PROCESS COMBINATION OF  THE HIGHEST WELD ENERGY WITH LOWEST WELD JOULES.

In contrast to all other available manual and automated arc weld processes, with TIP TIG you should always the have the potential to enable the highest possible weld quality that’s primarily derived from the highest possible fluid weld energy, and yet attain arc welds with the lowest possible  weld Joules.

Carbon Sts, or any steels and alloys, always the best weld quality. 

Any weld decision maker should wonder why the strange color,(TIP TIG low oxidation potential) and the small HAZ on this untouched carbon steel weld. Bonus, lowest weld fumes and lowest weld cleanup or rework requirement.

WELD QUALITY OR WELD & PART METALLURGY, REMEMBER  TIP TIG HAS BEEN AROUND FOR MORE THAT A DECADE, PERHAPS YOU SHOULD CONSIDER IT”S TIME TO TAKE ADVANTAGE OF OF THE NUMEROUS WELD BENEFITS DERIVED.

So the TIP TIG lowest possible weld heat input will produce welds with the least oxidation, which  means welds with the lowest weld porosity and also welds with the lowest distortion potential. As TIP TIG also provides arc welds with the smallest possible weld HAZ, this enables the best possible weld Impact properties and of course the welds will have the best possible corrosion properties and the least potential for Hot Weld Cracking.

Just a Mechanical action changes the TIG process.

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No useless TIG power source electronic bells and whistles that provide minimal weld benefits on steels, just a brilliant introduction by Plasch in Austria of a mechanical action on the continuous fed TIG wire that delivers the patented, TIP TIG  process.

THE PRIME PURPOSE OF A WELD IS FUSION. TIP TIG, ALWAYS ENABLES SUPERIOR WELD FUSION WITH ALL STEELS, THIS DRAMATICALLY REDUCES WELD REWORK WHEN NDT USED.

With the TIP TIG high energy, increased weld fluidity. agitated welds, you reduce the potential for both lack of weld fusion and weld porosity. As many alloy welds are sluggish in solidification TIP is especially beneficial in improving the weld fusion with all alloy welds.  

ALLOYS ATTAIN THEIR PROPERTIES FROM HEAT TREAT, AND THEREFORE WILL BENEFIT FROM AN ARC WELD PROCESS THAT ENABLES THE LOWEST POSSIBLE WELD HEAT.

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

2018 TIP TIG has  been around for more than a decade, however TIP TIG is part of a global industry in which process “change” is rarely embraced. To implement new weld technology that can produce real world application weld quality and weld cost benefits, needs to be driven by progressive management, engineers and supervisors.