TIP TIG Versus TIG, Pulsed MIG & Hot Wire TIG.

DC TIP TIG always provides superior weld quality and mechanical properties and less weld heat than both the traditional DC TIG and the Pulsed MIG process. TIP TIG is also much easier to use than TIG, & TIP TIG lowers DC TIG labor costs in the range of 200 - 400%.

2019. Emily Craig: From a weld process application potential, after studying the  TIP TIG process versus traditional DCEN TIG, Pulsed MIG and the Hot Wire TIG process now for more a decade, you will find the TIP TIG data and weld application potential available at this site, is from both a weld process and application evaluation, unique, practical, cost effective and comprehensive. Please note also that this is  the only global  site that for more than two decades has focused on the common  weld quality and cost consequences from lack of global focus on the benefits weld process controls and best weld practice expertise. 

The TIP TIG, Pulsed MIG and Hot Wire TIG weld advice and data I provide, is  based on  my weld application and process control expertise that I developed over 5 decades while assisting approx. 1000 companies in 13 countries with their manual, automated and robot  weld issues. My  weld data  is always honest, factual and provides numerous, practical cost effective weld  solutions. As I have spent hundreds of hours writing and rewriting  this TIP TIG section, and thousands of hours writing the MIG, flux cored and advanced AC – DC TIG arc weld data sections  in my  weldreality web site, I would appreciate that if you wish to use any of my original, copyright protected data, that you at least please request  my permission at, ecraig@weldreality.com.

After 70 years it was time for TIG to evolve, now  all that needs to happen is for weld shops need to catch up.

Tip Tig Brochure 022011

TIP TIG requires minimal  skills for all position welds, enables higher quality than any  TIG or Pulsed MIG weld, and enables the lowest possible weld heat with a 200 to 400% increase in hourly TIG weld production. 


Aug. 9 2019:  I am aware that  the technical weld process process details at this site may not get everyone as exited as I get when discussing TIP TIG  versus the AC/ DC TIG, Pulsed MIG and Hot Wire DC TIG weld differences and weld application potential, so  let me provide you in the first few  paragraphs, more than twelve years after it was introduced, some of  the unique TIP TIG prime weld Quality – weld Cost reasons that any company that requires  code quality welds on steels, alloy steels, alloy and many aluminum applications, simply cannot afford to ignore.

From welding submarines to aerospace components, or welds on turbine and  sub sea  parts, for decades with  code quality weld applications, when using the common arc weld processes such as GTAW (TIG)  – Pulsed MIG or Flux Cored, weld shops would often anticipate weld  issues, rework and rejects. Or possibly there would  be distortion, mechanical and corrosion concerns with the high strength steels,  alloy steels and  alloy applications.

As TIP TIG is a process that consistently delivers higher weld quality than possible with with the TIG and Hot Wire TIG process, and also provides the unique attribute of enabling the lowest possible weld heat on most applications, weld shops would do well  to step into the 21 st Century and evolve their weld quality and productivity expectations  with a process that is the evolution of  TIG, that process is TIP TIG. 

I want to start this section with the following statement.  In 2019, if any of the global weld shops involved with Aerospace, Defense, Oil or Power industry welds are still using manual or automated GTAW, Pulsed MIG or Hot / Cold Wire TIG for their daily code quality welds, then none of these weld shops  have the weld capability to produce the weld quality shown in the following video.


2019. FOLLOWING IS A TITANIUM WELD THAT NO GLOBAL WELD SHOP COULD  ACHIEVE IF THE  TIG  OR PULSED MIG WAS UTILIZED. 

 

The Way many titanium welds should be made.

I SET THIS TIP TIG WELD IN 2009 TO WELD TITANIUM WITHOUT A GAS TRAILING SHIELD & PRODUCE A WELD QUALITY  THAT WOULD MEET ANY CODE REQUIREMENT.


WHAT USED TO BE A COMPLEX TITANIUM WELD APPLICATION IS  SIMPLE WITH TIP TIG:  When welding  Titanium parts thicker than 3 mm with TIP TIG, in reality the application would be as simple as welding carbon steels. 

In the above video, in 2009, when I was setting the TIP TIG weld parameters for my business partner Tom to weld some Grade 2. Titanium scrap parts, the engineering manager from  the large Philadelphia Titanium fabricator that supplied the titanium test parts, asked me why I was not set up to use an argon gas trailing shield to protect his  titanium parts  from  weld / part oxidation. I smiled as I knew something that this engineer did not know then, and unfortunately most global engineers and managers ten years later, still don’t know.

Though this was the first time Titanium would be welded with TIP TIG in North America, I was well aware when I welding other heat sensitive alloys of the very low weld heat that was  always  attained through the silver and gold colors I was attaining on on both steels and stainless. The lack of oxidation that I had attained on both thin and thick parts was an indication to me that we would not  likely need a gas trailing shield which was usually  necessary to minimize the titanium weld oxidation concerns. Please go back to the titanium weld  above and note the untouched desired silver color of the  titanium  gauge weld that if welded with TIG or pulsed MIG would normally  retain high weld heat input. By the way as we were just setting our TIP TIG weld shop at this time, I had nothing that would correctly clean the  titanium parts, therefore these parts were welded with contaminated from cutting and forming, (the  reason for the weld  fumes).  


IF THE ABOVE TITANIUM WELD HAD BEEN MADE BY REGULAR GTAW OR PULSED MIG YOU WOULD HAVE SEEN MANY COLORS.

If regular DC GTAW had been used for the above titanium weld. The regular TIG manual  weld speed for this single pass,  3/16 – 1/4,  (6 mm)  horizontal lap weld would likely  be approx. 3 to 5 inch/minute,  with  weld starts and stops and a wire length change required. A gas trailing shield would have to be used, and there would likely be concern for  weld oxidation formation on the rear side of the welded titanium plates.  The time required to weld the above  length of 18 inches with TIP TIG at the weld  speeds of 24 inch/min  would have be less than a minute. The time required by With regular TIG, would be around  6 to 9 minutes.

2019: THAT TITANIUM WELD ABOVE IS NOT ACHIEVED WITH ELECTRONIC BELLS & WHISTLES, ITS SIMPLY A RESULT OF THE  WELD JOULES CAPABILITY OF DC TIP TIG, A PROCESS THAT ATTAINS IT’S LOW WELD HEAT AND HIGHER QUALITY TIG WELD BENEFITS FROM A PATENTED MECHANICAL ACTION.   

2019: DC TIP TIG VERSUS TRADITIONAL DC TIG WELD JOULES: The typical weld joules  if using  regular DC TIG for a titanium single pass weld on this 1/4 part thickness would be in the range of 35,000 to 40,000 J/inch.  In contrast, the weld heat generated with  TIP TIG on the titanium weld was approx. 5550 J/inch,  this low heat was  attained  from the much  higher weld travel speeds attainable with  TIP TIG. 

2019: DC TIP TIG VERSUS RP PULSED MIG WELD JOULES: What about TIP TIG versus Pulsed MIG and weld joules differences.  In contrast to many pulsed MIG welds,  the weld shop could anticipate approx. a 50 to 70% weld heat reduction. Also note the weld heat conductivity benefits of  DC Electrode Negative TIP TIG  with its higher weld speed potential versus the Reverse Polarity Pulsed MIG or Spray weld modes  are poorly understood by weld industry personnel that should be  looking for ways to reduce weld heat on heat treated applications.

Keep in mind that  while the Pulsed  or Spray MIG weld transfer modes will weld  faster than  TIP TIG, the Reverse Polarity MIG is using Electrode Positive, which  concentrates the MIG weld heat in the upper portion of the MIG plasma, ( around the continuous fed weld wire tip). While weld shops are aware that arc weld polarity  will greatly influence  weld / part heat input, you have to remember that for almost 70 years the traditional DC Electrode Negative TIG process which directs the TIG arc plasma energy towards  the part welded has rarely been able to benefit from it’s DCEN weld  polarity in which those TIG welded parts become a large heat sink (rapid weld heat conduction) for the DC TIG weld heat generated. The reason for the high TIG weld heats is simple, traditional TIG on most parts > 2 mm typically generates very low weld deposition rates and resulting slow arc weld speeds. So the weld reality has been with many  TIG welds, you would find that the slow moving Direct Current Electrode Negative TIG welds and  the much faster Reverse Polarity  MIG welds often generate similar weld joules.

2019: NOTE FOR THOSE OF YOU STILL USING WELD & MATERIAL SPECIFICATIONS AND CODE INFO. GENERATED IN THE 20th CENTURY: The typical weld joules  heat  input attained from Spray – Pulsed MIG, AC/DC TIG, have for many decades influenced  the weld  preheat, inter pass, and post heat recommendations. Also  weld filler metals specifications and the weld / part properties attained are based not only on the weld wire chemistry but on the filler wires weld quality potential and typical arc weld heat input generated With this info we end up with the typical arc weld mechanical or corrosion properties that have been attained for decades from the conventional  arc weld processes.  Then along comes TIP TIG,  a process that not only provides the highest possible arc weld quality, but also the lowest possible weld heat.  Think of the weld opportunities and the weld solutions. Think about how many  engineers in 2019 are daily dealing with weld quality or heat related concerns with their weld applications, and those concerns simply would not happen or be dramatically reduced  if they made use of the 12 year  old  TIP TIG process  

SO  FOR THE FIRST TIME IN THE HISTORY OF ARC WELDS, APART FROM THE HIGHEST POSSIBLE WELD QUALITY,  TIP TIG ENABLES EXTRAORDINARY  REDUCTIONS IN WELD & PART HEAT,  AND THIS IS ATTAINED FROM A MECHANICAL ACTION ON THE TIP TIG WIRE FEED THAT ENABLES A DRAMATIC INCREASE IN TIG WELD SPEEDS AND THE  DCEN POLARITY.

TIP TIG ELIMINATES THOSE OXIDE REACTIONS THAT INFLUENCE WELD POROSITY. When dealing with weld heat and oxide sensitive alloys, and lets say the weld shop  is considering using pulsed MIG,  apart from the concentrated high pulsed MIG weld heat from reverse polarity, pulsed MIG also requires reactive gases in the argon mix, such as CO2 or Oxy.  The reactive gases will influence, oxidation and  porosity on any weld application. In contrast to pulsed MIG, TIP TIG only requires straight argon, (should never require helium for any welds). 

Note: To every global weld shop that wants to produce code quality welds, the TIP TIG weld quality / weld heat benefits that apply to the above  titanium weld, would also apply to any steels, alloy steels, alloy steels and many aluminum  applications. 

THE ACCEPTANCE OF AN IMPORTANT  NEW ARC PROCESS IS INFLUENCED BY THE ABILITY OF THE WELD SHOP MANAGEMENT ABILITY  TO EMBRACE CHANGE.  WITH TIP TIG REMEMBER  THAT  CHANGE  WILL INSTANTLY ENABLE  DRAMATIC WELD & PART QUALITY IMPROVEMENTS WITH EXTENSIVE  WELD COST REDUCTIONS:

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?” these are not weld shop floor problems, they should be front office problem.

ALL POSITION WELDER SKILLS INFLUENCE WELD DEFECTS:  Welder skills play an important role in a new arc weld process acceptance.  Traditional DC GTAW  for example requires the highest arc welder skills. Weld shop decision makers need to be aware  that with someone who has never welded, that  TIP TIG would take less than two weeks to pass any code welders qualification test. For experienced TIG welders, it would take one or two days if taught correctly.

 THE ARMY, THIS LARGE SCALE  TITANIUM APPLICATION WAS BOTH COSTLY AND COMPLEX, IT WOULD HAVE BEEN SIMPLE WITH TIP TIG?

So when the Army wanted to make lightweight Howitzers out of Titanium, TIP TIG was available at that tome and I tried to inform them how this process would simplify the application and would cut  hundreds of millions of dollars of the Howitzer mfg. costs, no one listened. A decade later I doubt if any of the Army or any defense personnel involved in weld engineering decisions will be aware of the TIP TIG process, and especially the weld benefits it would bring to any alloys, all high strength steels, investment castings and  armor steels.


IN 2019,  MOST GLOBAL WELD SHOPS ARE STILL WELDING TITANIUM,  ALLOY STEELS, ALLOYS AND ALUMINUM  CODE QUALITY APPLICATIONS WITH  OUTDATED 20th CENTURY ARC WELD METHODS: 

Automated GTAW titanium

Typically all position, manual or mechanized Titanium TIG welds on parts > 3 mm, such as the above Army Howitzer, or welds on  USA Navy Titanium pipe welds, left) on Aircraft Carriers would be carried with DC GTAW that for 70 years has provided very low weld deposition rates, (often less than one pound/hr)  producing  typical pipe “fill pass” weld speeds in the 2 to 5 inch/min range. Those multi pass, low DC TIG  weld speeds of course generate high weld heat, and to minimize the effects of the weld heat oxidation on the titanium welds, and to also control the effects of weld heat on the HAZ,  there typically will be time wasted for inter-pass temperature controls, and the weld personnel will have to deal with cumbersome gas trailing shields that have been  essential for  GTAW Titanium pipe welds.

Tip Tig Stain1When  welds are made on Titanium, Stainless, Inconel, Duplex,or Hasteloy, or on any welded parts sensitive to weld heat heat, the as welded finished weld color will speak for itself. In contrast to regular DC TIG, depending on the part thickness, TIP TIG manual or automated, pipe fill pass weld deposition rates will typically be 200 to 400% greater than TIG, enabling  weld fill pass travel rates  typically in the 9 to 25 inch/min range. Most TIP TIG welds will reveal a silver to gold as welded color. Note. On most alloys and alloy steel  welds on parts over 1/8,  inter pass temp will  likely not required, also preheats are often reduced or eliminated.

WELDERS WANTED…. THIS IS WHAT AN ADD FOR TIP TIG WELDERS SHOULD LOOK LIKE… “WELDERS WANTED TO WELD  CODE QUALITY  TITANIUM, STAINLESS  AND DUPLEX VESSELS,  GOOD WORK ETHIC REQUIRED, WILLING TO LEARN,  MINIMUM WELDER SKILLS REQUIRED“. 
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Yes TIP TIG is easy to use, 
just like MIG, with TIP TIG you can have one or two hands on the torch, just point the torch and move. No  foot control required, weld start / stop data is automatic. With TIP TIG one process for the job. From the  pipe root pass to any all position welds, TIP TIG  makes those welds an easy task, and don’t forget when skills are reduced, weld  quality is increased..

WELD SHOPS TAKE NOTE.  THE FOLLOWING IS ANOTHER WELD THAT CANNOT BE PRODUCED BY ANY GLOBAL  COMPANY THAT WELDS STAINLESS, DUPLEX, INCONEL OR HASTELOY AND MOST OTHER ALLOY THIN PARTS. 

HEAT SENSITIVE GAUGE STAINLESS PARTS WELDED WITH TIP TIG.

If you work in the Aerospace, Power or Defense industries,  stainless, inconel, titanium, duplex inconel  and hasteloy welded parts are the norm. Please don’t waste you time having your welders trying to duplicate the above, simple gauge stainless fillet weld that’s made with TIP TIG.


Examine the above TIP TIG 16 gauge stainless fillet weld. In contrast to what TIG welders would do for these welds, note the TIP TIG weld speed which will be 5 to 8 times faster over this weld length of 18 inch. Note also the weld quality continuity and uniformity not attained by GTAW or pulsed MIG. Go back and look at the untouched  silver weld color that indicates the lack of oxidation, that enables the lowest weld porosity. With these welds, no cleaning, no spatter, no weld fume concerns. And of course the smallest possible weld HAZ which means the lowest weld distortion, the lowest weld stresses, and  lowest possibility of weld cracking. These are welds that cannot be duplicated with any  DC TIG or Pulsed MIG welds.

A SUMMARY OF SOME OF THE DC TIP TIG BENEFITS VERSUS TRADITIONAL DC TIG. 

[a] TIP TIG ENABLES FAR SUPERIOR WELD QUALITY THAN TIG.

[b] TIP TIG ENABLES THE LOWEST ARC WELD HEAT. PRODUCES THE  HIGHEST WELD QUALITY WITH THE LOWEST WELD HEAT ENABLES. THIS ENABLES  THE BEST POSSIBLE  METALLURGICAL PROPERTIES AND  LOWEST WELD DISTORTION & CRACKING POTENTIAL.

[c]  FOR ALL POSITION WELDS, TIP TIG REQUIRES  LESS WELDER SKILLS THAN BOTH TIG AND PULSED MIG, AND REQUIRES NO MORE THAN 3 WELD SETTINGS FOR ALL WELDS,

[d] IN CONTRAST TO ARC LENGTH SENSITIVE TIG, TIP TIG IS READILY SUITED TO MOST MANUAL, ROBOT AND  AUTOMATED WELD APPLICATIONS,

[e] TIP TIG  PROVIDES MUCH HIGHER WELD DEPOSITION RATES THAN TIG, DRAMATICALLY IMPACTING  BOTH MANUAL AND AUTOMATED DC TIG WELD SPEEDS  & LABOR COSTS. IN CONTRAST TO DC TIG, ONE  TIP TIG WELDER IN AN HOUR   WILL USUALLY DO THE WELD PRODUCTION OF 3 TO 4  DC TIG WELDERS.


OPTIMIZING WELD QUALITY &  REDUCING  WELD COSTS SHOULD  BE OF INTEREST TO ANY WELD DECISION MAKER.

I would like to start out by simplifying the extraordinary weld  cost savings  potential with the  TIP TIG process. Don’t forget that weld costs are of course influenced by weld deposition rates, weld rejects and weld rework, and  also by the welder’s skills.  Weld shops take note, all of the traditional arc weld processes such as traditional DCEN TIG, Pulsed MIG, Flux Cored or the SMAW  process, require higher all position welder skills than required with TIP TIG. As we are all aware, when hiring TIG welders, the slow weld speed cost consequences, the never ending weld start and stops and the welder skill requirements have a major  influence on both the weld quality and   hourly labor costs. Watch 5 TIG welders produce the same welded parts, and it will  be  their manual welder skills and different weld practices  that  will influence the weld quality attained


Note. Every business is aware that  in 2019, all position skilled weld personnel are in short supply. With TIP TIG you have a process that  requires the lowest all position welder skills and for every three or four TIG welders required , one TIP TIG welder will do the same production with superior weld quality. 

THE SLOWEST INDUSTRIES TO EMBRACE POSITIVE WELD CHANGE ARE TOO OFTEN THE HIGH TECH INDUSTRIES.

SO LETS LOOK AT THE  ANNUAL WELD DEPARTMENT BUDGET WELD COST CONSEQUENCES WITH A CHANGE TO TIP TIG: It would take about two hours to prove the following statement. “In a weld shop that employs mostly  DC TIG welders, with a change to the TIP TIG process, that weld shop should anticipate at least a  65 – 75% annual weld labor cost cost reduction in their weld department budget.

The TIP TIG  weld deposition and weld travel details that greatly influence weld costs are well documented below, however I want to get across both the the extensive weld costs savings potential and weld quality improvement  impact with a change from TIG to TIP TIG with any company that provides Code Quality steels, alloy steels,  alloys and many aluminum  welds. The following info. provides how I attained  a  70% weld cost reduction.

Fighter PlaneAs an example, lets take a Fortune 500,  aerospace or defense corporation that has many global plants that hire  traditional DC TIG welders for code quality weld applications.  One of the plants employs 10 DC TIG welders, five on each shift. The plant also employs two weld shop supervisors  to manage the two shifts.  The TIG welders earn  $30 /hr, and  mostly weld steels and alloy steel code applications. This companies typical weld  labor costs $60,000.00 / yr, and the welders  benefits are $8,000 / yr. TIG is slow process and overtime is the norm. The average overtime per-TIG welder was 10 hours a week at time and a half, 10 x  $45 hr = $450  x 50 weeks = ($22,500 / year). This generates an  annual TOTAL weld labor costs of $90,500.00 per/welder  x 10 welders. Add the  two weld supervisors at $80,000 /yr,  with their combined annual salary of $160,000.yr and the total weld labor costs for this  weld shop is $1,065,000. The TIG weld equipment  investment for 10 welding  units, approx. $78,000.

COMPARE THE ABOVE WITH TIP TIG WELD LABOR COSTS: Now for those still hanging in there, welding the same work at the aerospace plant could be done on one shift with three TIP TIG welders and one supervisor. No weld overtime required, and  the TIP TIG weld quality would be much higher. Three TIP TIG welders wage plus  benefits, 3 x $68,000 / yr = $204,000 / yr, plus one supervisor $80,000 / yr,  producing  a  yearly TIP TIG WELD LABOR costs of $292,000.  By the way with TIP TIG you would also reduce the annual argon TIG gas cost by at least 50%,  and take approx. 15 – 20% of the weld wire costs. The TIP TIG equipment costs depending on the power sources available in the shop would be in the range between  $50 to $80K. As you  you can see with the added weld consumable savings, its easy to anticipate  a 60 to 75% annual TIG labor cost savings would be anticipated. 

The above annual TIP TIG weld shop wages total is $292.000. The annual TIG weld shop wage $1,065.000.

Note: Please keep in mind, that with all position code quality weld applications, many Fortune 500 corporations will across the globe “in all their plants” sometimes employ HUNDREDS of DC TIG and Pulsed MIG welders. As for Pulsed Pulsed MIG and code quality welds. In  contrast to the TIP TIG process, for reasons listed below and also provided in the Pulsed MIG section, Pulsed MIG will always produce inferior weld and part quality with special concerns for the weld heat generated and weld fusion and porosity issues..


With TIG or Pulsed MIG don’t try to duplicate this manual TIP TIG single pass, untouched  stainless  weld.

Tip Tig Stain1

Fighter PlaneSOMETHING I FOUND OUT OVER THE DECADES WHILE ASSISTING MANY GLOBAL COMPANIES  WITH THEIR WELD ISSUES: Its unfortunately an ironic point that, “the higher the technical capability of  corporations, the more common the isolation of the front office managers and engineering  decision makers are from the daily manual or automated weld process decisions that are being made on the weld shop floor.” And as you will see in the “play around with weld controls weld shops, and with the why change the way we have always done it weld personnel”  lack of management & engineering weld process ownership often leaves the weld shops without the  impetus for progressive weld change, and too often those  the weld shops are stuck  in the 20th. Century with the weld processes, weld  practices, procedures and specifications utilized.

To enable the highest  weld cost savings and weld quality improvements and to put a stop to welders playing around with the TIP TIG weld controls, or using poor TIP TIG weld practice please consider my  TIP TIG, or MIG and Flux cored, Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs. 

As the weld quality improvements and weld cost reductions will be dramatic with process control expertise or TIP TIG, the question becomes, who in the plant management will step into the  21 st century & take the  WELD PROCESS OWNERSHIP that necessary to both drive and implement their companies  weld quality improvements and weld cost reductions? 

WHAT MANAGER DOES NOT WANT TO SEE WELD COSTS REDUCED AND WELD FAILURE RISKS & LIABILITY REDUCED?  You don’t have to be an accountant to understand the weld cost savings potential from TIP TIG. Its easy to see  that once the traditional DC TIG to DC TIP TIG process change decision is made in the numerous global companies that are using  DC TIG and Pulsed MIG for code quality steels and alloy steel welds, that the annual weld cost savings for many  large companies could be measured  in the millions. Also note that many companies will have the opportunity to dramatically reduce weld rejects and rework costs.

An important point also for many companies  is the ability with TIP TIG to dramatically  reduce or eliminate Weld Failure Risk and  Liability concerns. Remember TIP TIG should always enable superior weld quality than TIG or Hot Wire TIG, with less manual welder skills. And  by bringing  the TIP TIG a process into a weld shop, management should anticipate  more uniformity and consistency in their daily  weld quality attained. Lets  also not forget that another benefit with the TIP TIG process is that companies will not have the future worry of finding and hiring skilled TIG welders,  (always difficult and now redundant).

As for the weld quality and cost benefits attained from providing employees with Weld Process Controls – Best Weld Practice Expertise. Surly there is not one logical thinking manager, engineer or supervisor that believes their daily manual or robot weld quality and productivity optimization will come from weld personnel that have to “play around” with two MIG equipment weld controls that have barely changed in sixty years. By the way, it would take me about two hours at any global facility to prove the  TIP TIG  process, and also the benefits of weld process controls – best weld practice expertise on providing a weld quality uniformity and consistency never before attained.

 

TIP TIG PIPE ROOT.

HOW LONG DOES IT TAKE TO TRAIN SOMEONE TO USE TIP TIG?  For most welders the pipe root is the most difficult weld. So with TIP TIG you show the person who wants to weld how to walk the cup by resting the torch ceramic on the surface of the pipe groove and working that nozzle from side to side as the weld progresses upwards. No foot control and no feeding a weld wire.  Believe me that does not take more than a few minutes to train someone.

If the welder is a TIG welder it typically takes one to two days to learn all the TIP TIG best practices as provided in my program.  However something that should give every manager joy, in an industry in which its difficult to find skilled TIG welders, it takes about eight to ten days  to train someone Who Has Never Welded to become a TIP TIG weld expert and pass any code,(including ASME)  all position,  pipe  Welder Qualification Tests.

At most of the fortune 500 high tech corporations,  you will usually find minimum weld  focus on weld process controls and best weld practice expertise. This lack of focus adds dramatically to the daily weld quality, rework, rejects  and production costs. By the way any manager  that believes in the importance of engineering evolution, should wonder why their company is still likely using Weld Procedures &  Specifications that were likely generated in the 20th century, or why there is little focus by their companies on weld process control and best weld practices.

Note: My easy to learn TIP TIG – MIG and  Flux Cored,  Self Teaching / Process Controls – Best Weld Practice Training  programs require approx. 15 hours. These are a great tools to  train yourself or those employees that for decades think its normal to  “play around” with their weld controls.  Its no good purchasing  a new process such as  TIP TIG  and having  weld personnel struggle to use the process. It does not matter how experienced the weld personnel are, all weld personnel  benefit from my weld process control  – best practice training programs.  To get the immediate and dramatic  weld quality – cost benefits from this process, and to avoid weld personnel playing around with the TIP TIG weld controls, and also not using the best TIP TIG weld practices, consider spending  a couple of hundred dollars and get the worlds best TIP TIG  – ADVANCED TIG  – MANUAL & ROBOT MIG – FLUX CORED training program.

 Em’s TIP TIG, –  MIG (manual & robot)  – Flux cored,  Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs.


Not  interested in TIP TIG, but would enjoy the  most comprehensive  real world information on the flux cored process, the Pulsed MIG process and equipment issues, and which are the best MIG weld gas mixes that all global weld shops should use, then visit here.


LETS GET BACK TO TIP TIG AND TRADITIONAL DC TIG PLUS  PULSED MIG WELD FACTS:

In contrast to traditional TIG, when evaluating the traditional  DC TIG weld and application benefits,  its easier if you first understand the; 
[a] THE  TRADITIONAL TIG ARC PROCESS RESTRICTIONS, 
[b] THE TIG WELDER  SKILLS AND TECHNIQUE REQUIREMENTS,
[c] THE TIG APPLICATION LIMITATIONS.
Then compare DC TIG with the unique arc and weld metal transfer characteristics along with the weld application benefits attained with the TIP TIG process.

Note: DCEN (Electrode Negative) is used with  DC TIG welds on steels, alloy steels and alloys. In contrast, AC polarity, or Variable EN – EP  polarity can  used for TIG welds on  aluminum and sometimes alloys. The TIG weld polarity requirements apply to both traditional  TIG and  the TIP TIG process.

For seven decades, the manual DC TIG process has enabled the highest possible manual arc weld quality, however the TIG welder skills,  and weld  characteristics restricted  DC TIG from attaining the capability to be a cost effective,  easy to use, semi-automatic or fully automated arc weld process.  These attributes are attained with TIP TIG, however its important to also compare the TIP TIG weld benefits with  processes such as Pulsed MIG and  the automated Hot Wire TIG process. 

2019: TEN YEARS HAVE PASSED SINCE I INTRODUCED  THE TIP TIG PROCESS TO NORTH AMERICA. THE REALITY HOWEVER WHEN WELDING  MOST CODE QUALITY STEELS AND ALLOY WELD APPLICATIONS,  IS THE MAJORITY OF THE NORTH AMERICAN WELD INDUSTRY  DAILY PAYS AN EXORBITANT UNNECESSARY COST BY USING TRADITIONAL  DCEN TIG, INSTEAD  OF  THE TIP TIG PROCESS.  

A QUESTION THAT COULD BE ASKED OF  ANY WELD SHOP MANAGER, ENGINEER OR SUPERVISOR THAT DAILY PRODUCES A SUBSTANTIAL AMOUNT OF DC TIG WELDS, OR IS  CONSIDERING PULSED MIG FOR CODE QUALITY STEEL OR ALLOY WELDS;

[a] Why are you still selecting DC TIG or the pulsed MIG process that will that require higher all position weld skills than TIP TIG?
[b] Why are you still selecting DC TIG or the pulsed MIG process both of which will always produce inferior weld quality than TIP TIG?
[c] Why are you still selecting DC or pulsed MIG, when TIP TIG will enable the lowest weld / part heat providing the lowest weld distortion, the lowest weld stresses and the best possible weld & part metallurgical properties? 
[d] Why are you still selecting DC TIG, when the TIP TIG process will reduce your organizations TIG hourly labor costs  by approximately 70%?

There are numerous weld quality, part metallurgical and weld cost  benefits attained from TIP TIG, and most are addressed.

This Westinghouse TIP TIG welder is putting  350% more TIG wire into this weld than is possible with GTAW.

2019: TRADITIONAL TIG AND  OBSOLETE WELDER SKILLS: As TIG welders cannot consistently feed small diameter weld wires fast enough, the welders typically use large wire diameter wires, 1/16 to 1/8, (1.6 to 3.2 mm) are common. Part of a TIG welders “skills” and learning curve is to be aware of the TIG weld pool fluidity, and manually feed the large weld wire so it makes an intermittent, rapid contact with the small  rapid freeze fluid area at  the front edge of the TIG weld, and then be aware of  when to withdraw the wire from the pool so the plasma retains the required weld fluidity.

The DC TIG manual wire feed requirements, maintaining the correct arc length from the tungsten to the weld, avoiding contamination of the  tungsten with either the weld  and wire, understanding the weld pool fluidity, with the sometimes the use of a foot amp control,  have for seven decades been important  prerequisites of  the manual TIG welder’s skills, and those skill in reality for more  a decade have no longer been required with the TIP TIG process.

TRADITIONAL TIG COMBINES  POOR ARC PLASMA ENERGY DISTRIBUTION FOR THE WELD WITH VERY LOW WELD DEPOSITION RATES: Take at the left picture at how a good portion of the traditional DCEN TIG arc plasma energy is required to assist in melting  a small amount  of the large DC TIG wire tip, while  almost an equal portion of the TIG arc plasma is required to maintain a small fluid weld area. Its notable with the DC TIG welds, that as the TIG wire is dipped in the weld pool, it  absorbs energy away from both the fluid  part of the weld pool and also from the arc plasma. When you combine the “dual plasma DC TIG energy distribution requirements” with the DC  Electrode Negative  polarity in which the electrons are drawn to to the positive work, we end up with a DC TIG process that provides rapid freeze welds, arc length sensitivity concerns and very low weld deposition rates.  

Unfortunately over the last decade, many of the managers and engineers in the Power, Medical, Defense, Aerospace, Oil and Gas industries that are responsible for weld decisions, seem to be stuck with 20th Century weld processes, and unfortunately most are not  aware of the reduced weld risk, and extensive weld quality & cost benefits that could be derived for their organizations from the use of  either the manual or automated  DC TIP TIG process.


2019 FANCY GLOVES & JACKET & NEW TORCH & HELMET, USING THE OUTDATED 20th CENTURY GTAW PROCESS.

2018: WHEN A WELD SHOP UTILIZES THE ABOVE 70 YEAR OLD, DC GTAW (TIG) PROCESS INSTEAD OF  TIP TIG, EACH HOUR THEY ARE  PRODUCING  INFERIOR WELD QUALITY. EACH HOUR THEY ARE TYPICALLY PRODUCING 200 TO  400% LESS WELD. EACH HOUR THEY ARE USING  A PROCESS  THAT REQUIRES MUCH HIGHER WELDER SKILLS.  EACH HOUR THEY CREATE UNNECESSARY WELD HEAT AFFECTING  WELD/ PART PROPERTIES AND DISTORTION.

IN 2019, THE MAJORITY OF COMPANIES IN NORTH AMERICA THAT MAKE HEAT EXCHANGES ARE STUCK IN THE 20th CENTURY USING MANUAL OR AUTOMATED TIG. The poor quality “manual  TIG welds below were proudly displayed in a US, 2109 weld magazine. These are  heat exchange tubes and when you get sad manual weld quality like this, its one reason the companies that  make these products will turn to costly, automated TIG weld equipment. With welds like this, the  back plates are typically grooved, so the welds will typically require two or more weld passes per-tube. Note. On Heat Exchange welds. if the manual or automated TIG welds required two to three passes, in contrast TIP TIG depositing much more weld metal would typically require one weld pass.


REGULAR  MANUAL GTAW  HEAT EXCHANGE WELDS.

Regular Tig Heat Excchanger

Heat exchange tube  approx. circumference  9  inches.  Note the weld inconsistency as the welder has gone around the tube. 

Lets say for example with the above heat exchange welds that with the regular TIG weld stops / starts,  it took approx.  5 – 7  minutes for the TIG first pass, and 9 – 11 min for the second larger TIG pass. We end up with an average time of 15 minutes  for this one weld joint completion with two weld passes. In contrast, manual TIP TIG  would not only produce much higher quality welds that would look like they were made with automation, TIP TIG would take approx. 1 minutes to complete a weld such as below.  


TIP TIG  HEAT EXCHANGE WELDS.

Tip Tig Heat Exchange

Typical regular manual TIG weld speeds on welds like this would be usually around 1 inches/min. With manual TIP TIG  a minimum of  6 inch/min. Note the TIP TIG all position weld quality, weld continuity and consistency. Note also the weld tie-ins, the untouched weld lack of oxidation, &  almost no weld HAZ.


SO WITH TIP TIG the welder is again producing weld quality that looks like its produced with automated weld equipment. TIP TIG requires far less  manual welding skills than TIG. TIP TIG reduces weld cleaning and weld fumes. TIP TIG dramatically lowers the weld heat input. TIP TIG will reduce the number of  weld start stops, (common weld defect locations). TIP TIG  reduces the amount of  weld passes required. And after more than a decade since TIP TIG was introduced, thanks to ineffective weld management, most global weld shops are still using tradition TIG or wasting money on unnecessary costly,  automated  Hot  Wire TIG equipment.

TIP TIG on difficult small diameter heat exchange welds.

Nice on these difficult to weld, small diameter tube welds to use a process that enables two hands, a process that enables great control of the weld start and stop without a foot control. A process that continuously delivers the weld wire in the arc sweet spot from the weld start too the weld end. A process that always provides higher weld quality than TIG. A process that always produces  lower weld heat than any TIG or pulsed MIG welds.


IN THE 1960s, I  STARTED MIG, TIG & FLUX CORED WELDING AT MASSEY FERGUSON IN THE UK. IF I COULD TAKE YOU BACK  TO THAT TIME,  AND WAS  ABLE TO USE THE WELD  EQUIPMENT AVAILABLE, IN A FEW MINUTES,  I WO
ULD SHOW YOU  HOW LITTLE THINGS HAVE CHANGED AND   PRODUCE OPTIMUM MIG,  FCAW AND TIG WELD QUALITY AND PRODUCTIVITY THAT IN REALITY IS NO DIFFERENT THAN WHAT WILL  BE PRODUCED IN 2020  ON STEELS & ALLOY APPLICATIONS. THE TWO MOST IMPORTANT WELD CHANGES THAT HAVE HAPPENED OVER 60 YEARS, ARE PULSED MIG FOR THIN ALUMINUM AND TIP TIG FOR CODE QUALITY WELDS. 

A MISSING LINK OVER THE 60 YEARS. Thanks to the general  lack of global weld process controls and best weld practice expertise, for six plus decades, too many in the  weld  industry have relied  on weld sales advice. From my perspective, (Note I trained over 2000 weld salesmen in the US and Canada) weld sales advice is rarely the logical engineering route to weld process optimization and process ownership. My weld reality has been, that most weld shops are likely to get more realistic weld process control – best weld practice advice from a used car salesman.

IF YOU WANT THE BEST POSSIBLE WELD QUALITY WITH THE LOWEST WELD REPAIR COSTS, AND YOU WOULD LIKE AN ALL POSITION PROCESS THAT REQUIRES THE LEAST WELDING SKILLS, YOU MAY WANT TO RELY LESS ON A SALESMAN FOR WELD ADVICE, AND TAKE A LOOK AT  TIP TIG & ALSO TAKE A LOOK AT MY WELD PROCESS CONTROL – BEST WELD PRACTICE SELF TEACHING / TRAINING RESOURCES.

ABOUT THE SAME BS AS FOUND IN A USED CAR LOT.

No other high tech industry relies so much on unqualified sales reps. for process advice.


2019: PLEASE NOTE:  AS LINCOLN MILLER, ESAB, HOBART DID NOT INVENT THE TIP TIG PROCESS, A PROCESS THAT BY THE WAY ATTAINS IT’S PRIMARY TIG WELD BENEFITS NOT FROM ELECTRONICS BUT FROM A PATENTED MECHANICAL WIRE ACTION, THERE WILL NOT LIKELY  BE A WELD DISTRIBUTOR SALESMAN KNOCKING ON MOST COMPANIES  DOORS TO INTRODUCE THIS PROCESS. HOWEVER, THE WELD REALITY IS,  IF MANAGERS, ENGINEERS AND SUPERVISORS HAVE TO RELY ON A SALESMAN FOR THEIR COMPANIES WELD APPLICATIONS & PROGRESS, ALL  I CAN SAY IS, FOR GODS SAKE, IF YOU ARE INTERESTED IN ATTAINING  THE BEST POSSIBLES WELD QUALITY AND THE LOWEST WELD COSTS,  “STEP UP TO THE PLATE AND TAKE OWNERSHIP.” 


ssss2018: FOR A DECADE, ITS MADE NO ENGINEERING SENSE FOR MANAGERS & ENGINEERS TO REQUEST UNNECESSARY WELDER  SKILLS:
As the aerospace welder on the right indicates with his complex TIG alloy application, how many other global companies in 2019 are welding heat sensitive alloys and code quality components & using the obsolete, DC TIG weld process that produce pathetic weld production, high weld heat and requires high welder skills? 

Of all available manual “arc” weld processes, for the last seven decades, the traditional DC TIG process has required the highest welder skills, and those skills and weld practices vary greatly from one TIG welder to another.  The different skills and techniques that welders use in  feeding their  TIG weld wire, plus the common contamination and wear of the tungsten, and also the too frequent weld starts and stops which come with wire length changes, dramatically impact both the DC TIG weld quality and consistency.

Note: I should not  have to remind those that arc weld parts in the Aerospace, Defense, Power, Medical and Energy industries, of the importance of using an arc weld process such as TIP TIG which enable  minimal welder skills for all position welds, and produces the most uniform, consistent, highest possible, manual or automated  weld quality with the benefits attained from lowest possible weld heat

With  with TIP TIG manual welds, the welds  are being made with a “Semi-Automatic” TIG process that is readily Automated without the requirement for  costly, automatic arc length adjustment equipment. The TIP TIG  manual welder does not need skills to feed a weld wire. With TIP TIG, the weld wire is continuously fed  into a TIG plasma sweet spot, something not possible from  any manual TIG welder. The TIP TIG wire melt rate is both uniform and continuous, again something not possible from a  manual TIG welder. With TIP TIG no foot controls required and no  stopping of the weld for  a new wire length. With TIP TIG the weld wire is not fed close to the tungsten, its fed instead into the edge of the arc plasma periphery, avoiding the chances of tungsten contamination, and tungsten melting into the weld is also  dramatically reduced. Once a welder becomes familiar with TIP TIG,  its likely in a shift that they may only have to grind their tungsten once. 

FROM PIPE ROOTS TO PIPE FILL, LARGE OR SMALL PARTS, MANUAL OR AUTOMATED, YOU WILL FIND TIP TIG IS  AN EASY TO USE PROCESS AND REQUIRES NO MORE THAN “THREE WELD SETTINGS” TO JUST ABOUT WELD ANY ALL POSITION STEELS AND ALLOY STEEL APPLICATIONS FROM 16 GAGE TO ANY THICKNESS. TIP TIG PROVIDES ANY COMPANY FOR THE FIRST TIME SINCE ARC WELD PROCESSES HAVE BEEN DEVELOPED TO FINALLY PRODUCE FIRST TIME, DEFECT FREE WELDS. NO ERGONOMIC OR WELD FUME ISSUES.  NO METALLURGICAL OR DISTORTION ISSUES. REDUCED PREHEAT – INTER-PASS TEMP  OR POST HEAT CONCERNS. NO WELD CLEANING  & DON’T FORGET  THE  MINIMAL WELDER  SKILLS REQUIRED.


THE PRIMARY ARC WELDING PROCESSES SUCH AS MIG – TIG – FLUX CORED &  SMAW,  HAVE CHANGED LITTLE IN  SIX  DECADES, AND  THESE WELD PROCESSES  ACCOUNT FOR MORE THAN 98% OF THE GLOBAL WELDS PRODUCED DAILY. A logical question would be why would any manger or engineer responsible for welds, ignore a new arc weld process that can provides extensive weld quality and cost benefits, an easy to use  weld process that anyone who has never welded can learn in less than 10 days.

Minimal welder skills, no weld fumes,
no weld spatter, no weld cleaning, highest weld quality, lowest weld heat.

In the last decade, companies such as Siemens – GE – Philips – Toshiba,  have been looking for something not required. I noticed in May 2019, a “Welders Wanted” add from Philips Healthcare in New York. Philips makes MRI equipment, and part of the Philip’s welder’s job description is simply another indication how managers and engineers in the high tech medical industry are simply out of touch with weld reality.  Part of the Philip’s job description was that the TIG welders must be able to use two hands and two legs, (a requirement for the foot control and wire feed TIG skills). As indicated in the above video, with TIP TIG those welder skills were redundant a decade ago.  Also the Philips managers should be pleased to know that TIP TIG manual or automated welds will always enable superior weld quality than TIG or Pulsed MIG.  In contrast to DC. TIG. no feeding a weld wire, no foot control, no constant grinding of the tungsten, no more numerous weld starts & stops to change to  a new weld wire and  no  longer taking years to become a skilled TIG welder. And something that every manager should appreciate for every hour their  TIG welder is welding, the TIP TIG weld  will typically require approx. 10 minutes.


2018: THE “WHY CHANGE THE WAY WE HAVE ALWAYS DONE IT”  WELD SHOPS CAN CONTINUE TO PURCHASE MAGIC WELD GAS MIXES OR WELD EQUIPMENT TOO OFTEN LOADED WITH COSTLY, USELESS  ELECTRONIC BELLS AND WHISTLES, OR THEY CAN SIMPLY LEARN ABOUT PROCESSES AND PROCESS CONTROLS, AND  GET A GRIP ON THE REQUIREMENTS FOR WELD PROCESS OWNERSHIP WHICH WILL  ENABLE  POSITIVE COST EFFECTIVE WELD CHANGES FOR THEIR COMPANIES:

With it’s latest Inverter TIG equipment, Miller proudly announced with the  advanced electronics that it can speed a companies  DC TIG welds by 17%. What does that mean? Well your DC TIG welder is making a weld on 3/16 or 1/4 stainless at a typical travel rate of 3 inch/min,  that new Millers Inverter TIG power source now enables with the 17% increase in weld speed a new weld speed of 3.5 inch/min, yawn. In contrast,  when TIP TIG equipment is added to that Miller power source, it  usually enables 200 to 400 % in weld deposition rates that  enable 300 to 700% increase  in TIG weld speeds. Remember weld speeds influence weld & clad heat, and weld heat influences weld – part metallurgical properties, distortion, stresses and oxidation.

Its common in high tech industries, to find that the managers & engineers responsible for welds, will often not be aware of  the required  weld process control expertise and therefore struggle to attain weld process ownership.

 2018, I HOPE YOU ALSO FIND IT IRONIC, THAT MANY OF THE INDIVIDUALS  RESPONSIBLE FOR WELDED COMPONENTS IN HIGH TECH INDUSTRIES,  WILL OFTEN COMPLAIN ABOUT THE SHORTAGE OF SKILLED WELDERS, OR COMMENT ON THEIR WELD QUALITY AND COSTS CONCERNS,  YET  NOT REALIZE THE SOLUTIONS TO THEIR WELD CONCERNS WOULD BE  SIMPLE IF THEY WOULD TAKE SOME RESPONSIBILITY FOR WELD PROCESS OWNERSHIP, STOP LISTENING TO A  SALESMAN & DO A LITTLE RESEARCH AT MY WEB SITE   www.weldreality.com.


2018: WHEN HIGH TECH. INDUSTRIES, THE ARMED FORCES  & RESEARCH FACILITIES SUCH AS LOS ALAMO LABS AND COLORADO SCHOOLS OF MINES IGNORE OR ARE NOT AWARE OF AN IMPORTANT ARC  WELD PROCESS THAT’S BEEN AVAILABLE FOR A DECADE,  WHAT DOES THAT SAY ABOUT THOSE RESEARCHERS THAT ARE MAKING THE WELD DECISIONS? 

Hundreds of millions of dollars would have be saved on any LNG construction, offshore or sub-sea projects, if the engineers responsible made the right weld decisions and stopped using  traditional DC GTAW and Pulsed MIG, and instead used TIP TIG on most of their code quality welds.

Thousands or millions of weld labor hours wasted on building projects like this. 

FOR THOSE  LOOKING FOR NEW BUSINESS  OPPORTUNITIES OR FOR RAPID WELD COST QUALITY / PRODUCTIVITY IMPROVEMENTS? Weld shop managers, engineers and supervisors might want to wake up to the weld quality & productivity benefits attained by TIP TIG, these are not the nickel and dime, hard to measure weld benefits that are usually proclaimed  with the latest electronic Inverter DC TIG or Pulsed MIG equipment when welding  steels and alloy welds. The highest all position weld quality and lowest weld heat means minimal concerns with even the most complex alloys.  The beneficial weld process  attributes from the easy to use  TIP TIG process, enable game changing weld quality / production benefits that can  dramatically impact any weld shop’s manual and automated weld application capability, think about the cost benefits from zero weld rework.

THE PULSED MIG  ACHILLES HEEL: When it comes to delivering optimum manual arc weld quality, many steel and alloy steel welds are  made with the manual Pulsed MIG process, with it’s weld fusion, porosity, spatter, arc stability  and weld heat concerns. For more than three decades, many companies  simply have not  understand why Pulsed MIG can be  a poor process choice when welding code quality steels and alloy steel parts > 4 mm, and especially welding alloy steels such as stainless and duplex, which have sluggish, slower weld solidification characteristics. 

2019: The most critical defect any weld can have is lack of weld fusion and with many pulsed  MIG welds you will find  manual weld fusion concerns especially on fillet and groove welds on parts 3/16 plus.  I have written three books on the weld fusion concerns with pulsed MIG, and  for twenty years my weldreality.com web site has been presenting the pulsed MIG steel weld issues  along with evidence of the poor pulsed MIG weld results. 

PULSED MIG AND LACK OF WELD FUSION: There are two primary factors why Pulsed MIG will at times result in weld fusion issues. 
[1] Pulsed MIG has to use a “low back ground current” to form and sustain the weld droplet and transfer. In contrast to MIG Spray transfer, the pulsed MIG back ground current takes weld energy away from the pulsed weld. To attain a higher energy pulsed MIG weld, the welder  would  have to turn the wire feed up and increase the weld deposition rates, (increase weld travel rates).  From a cost perspective, high deposition rates are  a good feature of a weld process. From a weld fusion  perspective, increasing weld speeds does not enhance weld fusion capability.

[2] In contrast to SMAW (stick) and DC TIG , Pulsed MIG enables all position welds at much higher weld deposition rates. A welder could weld a 6 mm wall stainless pipe (fill passes) with pulsed MIG, and  readily attain a weld deposition rate of  6 to 10 lb/hr. with typical manual weld travel rates on the vertical up welds usually between 10 and 15 inch/min.  The same vertical up, pipe fill pass welds made with DC TIG or the SMAW process would typically be delivering approx. one pound/hr, with weld travel rates of 1 to 3 inch/min.

WELD DEPOSITION & TRAVEL RATES AND WELD FUSION: Note on the importance of weld travel rates and weld fusion: Its the low weld deposition and resulting  LOW WELD TRAVEL RATES that enable the time required for all position weld fusion to occur with both the TIG and SMAW process. The all position weld fusion that occurs with these two low deposition weld processes is usually equal or superior weld fusion than that possible with the higher weld deposition, much faster weld travel rate, Pulsed MIG process. However from my perspective the weld speeds attainable with TIG and SMAW are too slow while the pulsed MIG travel rates are too fast. Manual or automated welds, there is only one process that provides the ideal weld speeds, with the highest weld energy, and that process is TIP TIG.  

One easy to use process. No spatter, no fumes, no weld defects from pipe or plate root to fill. It would take 7 to 8 TIG welders to achieve in one hour, what we trained these two TIP TIG welders to attain for the Chinese National Oil Company welding sub-sea pipe. 

WHILE SOME IN AMERICA SLEEP: It was ironic that our first major customer for TIP TIG  who came to at our Philadelphia Naval Yard facility, was the Chinese National Oil Company with a sub-sea pipe weld and clad application.


The following are logical reasons why TIP TIG will provide superior weld fusion and lower weld porosity than any other arc weld process.

[] TIP TIG ENABLES HIGHER WELD ENERGY THAN BOTH DC TIG AND PULSED MIG.
[] TIP TIG IS THE ONLY ARC PROCESS THAT AGITATES THE WELD POOL SLOWING THE WELD SOLIDIFICATION WHICH NOT ONLY BENEFITS WELD FUSION AND REDUCES WELD POROSITY, IT ALSO ELIMINATES SLUGGISH ALLOY  CONCERNS.
[] TIP TIG PROVIDES  WELD SPEEDS SUITED TO ATTAIN WELD FUSION, SLOWER THAN PULSED MIG & FASTER THAN TIG.
[] TIP TIG REQUIRES LESS ALL POSITION WELDER SKILLS THAN TIG AND PULSED MIG.
[] TIP TIG ONLY REQUIRES ONE PROCESS FOR ROOT AND FILL ON ANY THICKNESS.
[] TIP TIG PROVIDES SOMETHING THAT TIG CANNOT PROVIDE, IT PROVIDES CONSTANT, UNIFORM  MELTING OF THE WELD WIRE DELIVERED TO THE SWEET ARC SPOT.

Few global weld decision makers will be aware of the TIP TIG weld capability and weld benefits as both a manual, semi-automated process, or fully automated arc weld process. Few will be aware that TIP TIG is an easy to use process especially with all position welds. Few will be aware that it typically takes three to four DCEN TIG welders to do the work that one TIP TIG welder can do each hour. Few will be aware that TIP TIG will always provide superior weld quality than DCEN TIG, Plasma, Hot Wire TIG, Hybrid MIG and the Pulsed MIG process. Few will be aware that the DCEN TIP TIG process always enables not only the highest arc weld / part quality capability but also the  lowest possible weld and part heat enabling  the lowest weld distortion and never before attained  metallurgical properties. 

2018: The bottom line in the why change the way we have always done it,  and give me some time to play with the weld controls,  or lets get weld advice from a salesman, weld industry, is that there is an excellent opportunity for front office weld decision makers to enable  dramatic weld quality improvements and cost reductions, for their organizations. However to attain those weld quality / cost benefits,  front office personnel  would have to do something many  are often reluctant to do, step up to the plate, take process ownership, learn and  embrace a 21st century weld process called TIP TIG (my TIP TIG program has all the training and procedure data you need for any application).  

Consider providing yourself or employees with one or more of my TIP TIG – Advanced TIG – MIG – Flux cored or Robot MIG Weld Process Controls – Best Weld Practice, Self Teaching / Training Programs. By the way, why the above submarine? If like me you have an interest in  the never ending, dramatic, inexcusable weld cost consequences for the Navy and its prime contractors when they build subs or any sea going vessels, scroll down.  For those that want more info. you can call me at 828 337 2695 Eastern time.  For those like me  that don’t have a life and love this stuff keep on trucking.  


Traditional DCEN TIG Arc and Weld Wire influence on both the TIG weld Energy  and weld Deposition. 


TIP TIG effective on both small and large weld applications. No fumes, spatter, or distortion issues

SEVEN DECADES OF RESTRICTED THE  WELD APPLICATION  POTENTIAL:  The DCEN TIG low weld deposition rates have for decades restricted the TIG weld  capability and weld application potential. No one wanted to use traditional TIG on large weldments or thick weld applications so they would usually turn to MIG and Pulsed MIG and and always attain inferior weld quality, along with weld fumes, spatter or  weld heat concerns. In contrast, on the left, these welds were made with TIP TIG, (note the one hand and no stainless fumes) and the TIP TIG is producing superior quality than  possible TIG with lower weld heat and weld fumes than any process.  

Note: An application such as this on the lest would typically be welded with MIG Spray or Pulsed MIG, often resulting in  weld fusion, porosity quality, spatter, weld fumes and distortion concerns.

LOW DC TIG WELD DEPOSITION RATE CONSEQUENCES: So since it’s introduction,  a prime issue with DCEN TIG welds that require filler metal has been the very low weld deposition rates,  slow weld speeds and numerous weld start / stops. The DCEN TIG, large diameter 1/16 to 1/8 (1.6 – 3.2 mm)  weld wires, and the manual wire dipping action into the welds typically results in average  TIG weld deposition rates of less than one pound / hr. If the manual TIG welder utilized smaller weld wire diameters such as 0.035 or 0.045, (1 – 1.2 mm), the welder would find they lack the ability to continuously feed the small diameter wires in a controlled manner at weld deposition rates greater than that attained with the easier to control, much slower fed larger diameter wires.


Question: Em, as weld deposition rates are a large factor in weld costs, can you provide more detailed info. on the typical average weld deposition rate capability with manual  DCEN TIG welding?

Answer. An average DCEN TIG manual weld deposition rate attained with a 1/16 or 3/32, (1.6 – 2.4 mm) steel or stainless wire is approx. 1 lb / hr with a 60 minute arc on time and typically a DCEN TIG welders arc on time may average between 10 – 20 minutes. Lets say the TIG welder is feeding the common 3/32 steel or stainless TIG wire  into the weld  pool at  a controllable, approx. 8 inch minute, (20 cm/min) which delivers approx. 1 lb/hr with 60 minutes arc on time. If  the welder decided to try and feed a smaller 0.035 (1 mm) wire. To attain a pound an hour with the 0.035 steel or stainless wire, the welder  would require that the  TIG welder continuously feed the  0.035 wire around 70 inches per-minute for 60 minutes, (not going to happen with traditional TIG). More on this subject below.

HIGHLY SENSITIVE ARC LENGTH & LOW DEPOSITION RATES DON’T MAKE A GOOD SEMI OR AUTOMATED PROCESS: With DCEN TIG, the use of low – medium weld current, the use of large wires and the wire  placement in the arc plasma can result in rapid freeze welds that can interrupt the electron flow, creating “arc length sensitive”, conditions. Arc length sensitivity  and low weld deposition rates have for decades made the DCEN TIG process unsuited as either a semi-automatic or fully automated arc weld process. When used for weld automation the traditional DCEN process typically requires  costly automated arc length equipment and the welds are still made with very low deposition rates. 

In contrast  to DCEN TIG, the DCEN TIP TIG process provides; 
[a] TIP TIG: A preheated, small diameter, continuous fed  weld wire that melts at the plasma outer periphery  taking minimal heat from the arc plasma and allowing more  energy to the weld pool.
[b] TIP TIG: The  higher energy weld pool is slightly agitated, both influence a reduction in the  weld solidification rates.
[c] TIP TIG: Greater weld deposition rates that allow the use of  higher weld current.
These weld energy factors  will in contrast to DCEN TIG produce welds with more fluidity, welds with a more intense & wider arc plasma, factors  which combine to  reduces arc  length sensitivity. This enables TIP TIG to be  both a semi-automated and fully automated arc weld process

THE WORLD’S HIGH STRENGTH STEELS AND ALL ALLOY STEELS ARE ALL INFLUENCED BY HEAT TREATMENT.  TIP TIG IS THE  ONLY ARC WELD PROCESS THAT CAN MINIMIZE THE NEGATIVE WELD AND PART METALLURGICAL INFLUENCE PRODUCED BY ARC WELD  HEAT.

WHY MIG CAN NEVER COMPETE WITH TIP TIG WELD QUALITY AND WITH TIP TIG METALLURGICAL PROPERTIES. For seven plus decades, a unique attribute of the high arc temp. traditional DCEN TIG process, has been the “Electrode Negative” weld transfer that has the potential to promote rapid weld heat conduction into  the Positive Work. However the DCEN TIG weld application reality has been that the metallurgical weld and part benefits that could have been from rapid  TIG weld heat conduction, was in  in most cases greatly restricted as the very low DC TIG weld deposition rates  usually  result in “very slow weld speeds”  that are the prime factor in retaining the high TIG weld heat.

In contrast to traditional DCEN TIG and DCEN TIP TIG process in which electrons flow from the Negative tungsten to Positive work, both MIG (pulsed MIG on left) and Gas Shielded Flux Cored welds use Reverse Polarity Electrode Positive (EP)  So with EP MIG polarity, the electron flow is from the positive work to the tip of  the continuous fed MIG weld wire. Electrode positive polarity concentrates the majority of the arc plasma energy around the positive MIG and flux cored wire tip which enables rapid melting  of the weld wire, producing typical MIG weld depositions rates that can be as high as 10 to 14 times than that attained with traditional DC TIG.  Even with the greater MIG and flux cored weld deposition rates that enable much greater weld speeds than DCEN TIG welds, that concentrated energy retention in the MIG arc plasma results in MIG and flux cored welds that typically produce Large Heat Affected Zones. The faster MIG and flux cored weld speeds and the use of reactive gases such as CO and oxygen in the MIG argon mixes can produce welds with  lack of fusion, internal porosity, spatter,  surface oxidation and weld fume concerns. With many alloy steel MIG weld applications, there is concern with larger weld heat affected zones, and welds & parts subject to high stresses and distortion. 

So now we can examine what weld benefits are produced with a DCEN (straight polarity) TIP TIG, a process that can produce much higher weld deposition rates and faster weld speeds than TIG and this enables the lowest possible arc weld joules.  More on the important subject of weld heat  to follow.

To change that 70 year old  DCEN TIG manual process into the easier to use, much higher weld deposition, semi-automatic or automated TIP TIG process, dramatic, innovative TIG process changes were required by the inventor  Plasch, Austria. However its one thing to change the weld dynamics of an arc weld  process and another thing to evaluate the often subtle differences and weld process and application benefits attained with TIP TIG against the competing, commonly utilized  ac weld processes such as  DC TIG and Pulsed MIG, and this is my area of expertise, its  what I have done for a living in more than a 1000 weld shops in 13 countries.

For those like myself that love to look at what goes on in the depths of a weld arc plasma, and examine in detail the weld transfer characteristics of the weld metal being deposited, please note in the  left DCEN TIP TIG video, how in contrast to the manual DCEN TIG weld below, the TIP TIG, constant fed, smaller wire diameter melts and forms droplets at the Outer TIG arc Plasma Periphery. This weld drop formation and the unique shaken wire droplet detachment enables the majority of the DCEN TIP TIG plasma energy to be consistently applied on the weld surface.

NOTE REMEMBER HOW A TRADITIONAL DCEN TIG WELD HAS TO UTILIZE A LARGE  PART OF THE PLASMA ENERGY TO KEEP THE WELD SURFACE FLUID AND AN ALMOST EQUAL  PART OF THE PLASMA TO MELT THE WIRE TIP. ALSO NOTE THAT THE DCEN TIG PLASMA WIDTH AND DENSITY BEING PRODUCED IS ALSO  INFLUENCED BY THE LOW WELD DEPOSITION RATES WHICH RESTRICT THE WELD CURRENT UTILIZED WHICH  INFLUENCES THE PLASMA WIDTH AND DENSITY.

TIP TIG BENEFIT: It’s not just the small diameter TIP TIG wires, or the unique wire feed angle that places the TIP TIG wire at the outer plasma periphery (enables most of the plasma energy to be directed on the weld and part surface) that enables the  small TIP TIG weld drops to transfer across the arc plasma into a weld surface which attains  more energy than any DC TIG weld,, that are distinctly different than DCEN TIG, its also the patented TIP TIG “Wire Vibration” and resulting small “Weld Droplet Agitation” that enables the weld drops formed  on the TIP TIG wire tip, to rapidly detach and transfer into the fluid weld area providing  a slight agitation to the pool that can slow the TIG weld solidification  reducing weld porosity potential to the lowest degree and also enable the best possible arc weld fusion capability.

I would like to emphasize what makes TIP TIG unique.  Without the TIP TIG wire vibration that results from the patented wire feed action, those small weld drops on the wire tip may be slow to detach, or not detach and grow in size until the continuous fed weld wire  runs into the weld pool disrupting both the wire feed and causing weld transfer issues.

The DCEN TIP TIG preheated Hot Wire(HW) and agitated weld drops when transferred into the fluid weld, create a slight stirring action of the puddle which assists in slowing the weld pool solidification. Apart from the current delivered to the tungsten from the TIG power source, the HW  power source  typically also delivers  on average approx. 70 to 100 amps that heats the weld wire  before it enters the arc plasma. The DCEN TIP TIG  HW amps, plus smaller wires typically delivering  100 to 400% more weld than DCEN TIG. Remember more  weld wire increases the potential for “increased weld current” than that possible  with traditional TIG welds. 

In contrast to DCEN TIG, the increased DCEN TIP TIG weld current capability, the HW amps,  and wire feed agitation result in  welds with that typically will have a wider more dense arc plasma, welds with increased weld surface fluidity, welds that will attain superior weld fusion and the lowest  weld porosity, welds with  increased arc stability and decreased arc length sensitivity. Also the capability to  produce DCEN  higher weld speeds enables the lowest possible weld joules, the smallest possible weld HAZ  and the least weld oxidation. These achievements  enable TIP TIG to be an easy to use,  “all position”,  SEMI-AUTOMATIC or  AUTOMATED  TIG  process  that is providing weld and  part metallurgical application benefits never before attained in the weld industry.

  

TIP TIG, unique weld attributes and  unique weld and part benefits.


Lets  further evaluate the TIP TIG manual and automated weld / part application benefits between the following three widely used arc weld processes, and also discuss the weld shop reluctance to change which is common throughout the global weld industry.

[1] Traditional Manual DCEN TIG.
[2] Automated DCEN Hot Wire TIG.
[3] Reverse Polarity Pulsed MIG.


2019. WHY CHANGE THE 70 YEAR OLD WAY WE HAVE ALWAYS DONE IT?  Since the 1940’s, DCEN TIG has been attaining the highest manual arc weld quality, however for more than a decade, TIP TIG has been a superior semi-automatic and automated arc process, providing many weld and application benefits. 

Great weld quality with numerous weld shop issues & restrictions.  

For 70 plus years, DCEN TIG above changed little, however from arc welds on submarines or spaceships or welds in nuclear plants, DCEN TIG has  been the arc weld process of choice when manual code quality steels, alloy steels and alloy welds were required.  


2019: Its been approx. 10 years since DCEN TIG evolved into a process called DCEN TIP TIG, however a primary issue in  the global  weld industry has been the slow acceptance  of  the TIP TIG process, and the weld reality has been that many companies that use traditional DCEN TIG are missing out on an opportunity for their companies to extend their weld application capability and make dramatic weld quality improvements with  extensive weld cost savings.  Its important to also note that out of all the common arc weld processes daily utilized, the DCEN TIG  process has  required the “highest manual welder skills” that when combined 
with the lowest weld deposition rates  typically produces the “highest arc weld labor costs”.

Few in mfg. facilities like change, however when that change can dramatically improve weld quality and drive down weld costs, who in the front office is going to take ownership and drive the change?


One hindrance against weld shop progress and TIG evolution, is often weld shop attitude. Those that know me will be aware from my arc weld  process controls  – best weld practice books, 40 plus weld articles, and process control training materials and workshops,  would be aware that for more than three decades, I have been more than a little frustrated with; 
(a) the global, lack of management and engineer weld process ownership, 
(b) the why change the way we have always done it attitude, 
(c) the play around with the weld controls weld shop acceptance,
(d)  the reliance on a weld salesman for weld advice,
(e) the lack of weld process controls and best weld practice expertise.
With the above in mind, I would like to  start this blog on the now approx. decade old TIP TIG process, by asking a question.

“How long do you believe it should take experienced global weld decision makers to recognize the superior weld quality capability, the improved part mechanical or metallurgy properties and dramatic weld cost reduction benefits derived from a an arc weld process such as TIP TIG”? 

[] TIP TIG enables the lowest possible all position welder skills,  
[] TIP TIG always provides superior weld quality than manual TIG, and also Automated Hot Wire TIG and the Pulsed MIG process.
[]  TIP TIG while providing the highest possible arc weld quality, also provides the lowest possible weld heat. This unique combination enables extraordinary weld quality & part metallurgical benefits never before attained in the welding industry. 
[] TIP TIG with providing the lowest possible arc weld heat enables the lowest possible weld stresses and distortion.
[] TIP TIG with the lowest possible weld heat and  inert gas enables the lowest possible weld fumes.
[] TIP TIG dramatically lowers hourly labor costs from increased TIG weld productivity 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.
[] TIP TIG requires less all position welder skills than any of the traditional arc weld processes.

As someone who has been requested by frustrated managers to solve their weld problems and improve their weld quality and productivity in over a 1000 weld shops in 13 countries, I am well aware that the majority of the companies employ front office personnel that lacked the Weld Process Control – Best Weld Practice expertise that’s necessary for front office weld process ownership.

In  many companies, the front office personnel responsible for the weld shop  will often  rely on the weld shop personnel that when not playing around with their weld controls, will be asked to evaluate new weld equipment or consumables that’s typically recommended by a sales rep. The weld personnel will rarely have weld process control expertise, and that sales rep will usually have had  no previous experience in running a weld shop.

As the TIP TIG process was not invented by the major global weld equip. manufactures, it’s unlikely a weld sales rep will turn up at your facility and  discuss, or even be aware of the weld benefits of the TIP TIG process.  Also, it’s not likely that any company that has to seek arc weld process advice from a weld salesman, will be anxious to seek out new weld technology that’s not introduced by the conventional weld distributors. However as the useless politicians in Washington keep informing us, “it’s time for change”. And let’s face it! there should be no room in the highly competitive, global weld industry for arc weld process confusion, weld process ignorance or weld process apathy, especially  in any business in which the arc welds play an important role in their organization.

The DCEN TIP TIG process, is a unique arc weld process that provides a continuous fed, preheated and agitated weld wire into a DCEN (electrode negative) arc. Variable polarity TIP TIG can also provide remarkable TIG weld benefits.

With the TIP TIG  there is a relationship between the TIP TIG wire diameter, the continuous fed wire feed rates, the wire to tungsten placement, the tungsten size, profile  and current utilized. To attain weld optimization  with TIP TIG,  there are specific techniques and best weld practices that should be applied. All of these requirements are provided and simplified in my TIP TIG process control and best weld practice self teaching / training program provided below.

WHILE SOME IN AMERICA ARE ASLEEP AT THE WHEEL:

It’s ironic that the first customer for  TIP TIG at our USA facility, was  the “Chinese National Oil Company”. 

With the inconel ID and steel pipe OD, TIP TIG, one weld process for root to cap. Pipe welds without weld defects were the requirement. With each TIP TIG welder producing 300% more weld than a TIG welder, it takes a few minutes for these pipe welders to complete the  Sub-sea pipes. Two hands on the torch enables more controls. It’s nice not have a TIG wire getting in the way and not having to use a foot control. No spatter, no weld cleaning and no weld fume concerns in the confined ship area.


TIP TIG and Welder Skills:  AS the TIP TIG weld wire does not have to be fed manually, and a foot amp control is not necessary,  in contrast to regular TIG, the TIP TIG process dramatically reduces welder skills.  However to attain the full TIP TIG weld process and weld application potential, and to also break the common weld shop “play around”  with the weld controls approach to many arc welds, it would be beneficial if  in 2019 that management take a role in process ownership and ensure that both the TIP TIG process controls and best weld practices are learnt. Remember to learn the “all position” TIP TIG pipe welder skills would take a TIG welder  between 1 to 2 days. And to train someone with someone who has never welded with any process, it would take them with the TIP TIG process, if taught correctly, 3 to 5 days to pass any code pipe welder qualification test.


TIP TIG and Weld Practices:  No matter what the skill level of the welder is, the weld personnel should learn the unique TIP TIG weld practices, techniques, and the few required optimum weld settings. These are available in my TIP TIG Self Teaching – Training  program. This program requires approx. 10 to 12 hours. 

Em’s TIP TIG, or MIG and Flux cored  Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs.

As I write this in 2019, I hope this blog will help take some of the weld process and application confusion out of the TIP TIG process. I also hope that the TIP TIG info and application data at this site speeds up the acceptance of  this unique, important weld process and enable weld decision makers to be aware of  where DCEN TIP TIG process  belongs throughout the global weld industry.

I recognize that while the lack of Manual and Robot MIG weld process control expertise and best weld practices maybe an acceptable way of  life with the majority of front office weld decision makers in the global Auto & Truck industry, an industry that is used to daily accepting 30 – 60% daily robot MIG weld rework and extensive daily robot down time. However this lack of expertise should not be considered acceptable in weld shops that produce code quality welds. Weld shops that have an interest in enhancing their company’s weld capability and reputation. Weld shops that have an interest in reducing their weld costs and increasing profits. 

You don’t need to be a rocket scientist to figure out that the global lack of arc weld process controls &  best weld practice expertise, along with the too common reliance by weld shops for weld  advice from sales reps, would influence the weld shop and the front office culture and possibly have  a negative impact on the acceptance of  a new arc weld process such as the TIP TIG. 

Sales Influence on weld shops: Lets face it, when weld sales reps are required to guide key weld shop decision makers on arc weld equipment or consumables, products that in reality have changed little in decades, this is usually an indication that the company lacks the ability for Weld Process Ownership. When this expertise is lacking, someone will pay a steep price. 

MIG – FCAW – Advanced TIG – TIP TIG or  ROBOT MIG, every weld shop  will benefit from focus on Weld Process Controls and Best Weld Practice Expertise.


AN  INDUSTRY  THAT  RELIES ON INEXPERIENCED  SALES ADVICE TO RESOLVE THEIR WELD PROCESS ISSUES, PAYS A PRICE: 


Costly MIG power source Bells and Whistles: It’s not difficult to comprehend that much of the traditional Pulsed MIG weld equipment purchased over the last three decades, will have been purchased as a result of weld sales influence, and as a result of dubious product marketing weld claims from weld equip. mfgs.  The MIG equipment purchased would often be loaded with costly, useless electronic bells and whistles, circuit boards that rarely influenced the weld quality or productivity, circuit boards that however typically enabled the weld equipment and distributor’s  to increase their MIG power source profits.

Salesmanship also has influenced  the purchase of  weld consumables. For example, instead of the four MIG gas mixes required for all global MIG welds, we have more than 40 MIG gas mixes to choose from. (By the way I was a key writer of the AWS MIG gas specifications). And instead of using MIG wires many companies will often purchase unnecessary and more costly, Flux Cored or Metal Cored wires. 

What makes TIP TIG Unique? In contrast to many of the weld power sources produced in the last two decades, the DCEN TIP TIG process does not derive its increased TIG weld quality productivity and weld application capability from a weld power source loaded with  electronic bells and whistles. TIP TIG DC weld current is derived from a conventional,  suitable, 300 to 500 amp DC TIG power source. That TIG power source is combined with a patented TIP TIG Wire Feed delivery system,  plus a   small Hot Wire TIG power source and a unique torch is provided.


The TIP TIG Mechanical Wire Action drives TIP TIG benefits: Through a patented mechanical action, the TIP TIG wire feed drive roll mount goes back and forth at high speed. This action on the wire creates a restricted tension and release on the continuous fed weld wire. The mechanical action on the TIP TIG continuous fed wire creates an agitation effect on the weld wire, which when viewed is similar to a vibrating guitar string. The pre-heated agitated TIP TIG weld wire is fed through the unique TIP TIG torch that delivers the wire to a specific point near the tungsten.


TIP TIG WIRE AGITATION AND WELD BENEFITS:

TIP TIG Wire Agitation enables benefits. As the TIP TIG weld wire makes contact with the outer periphery of the TIG arc plasma, the wire tip melts and a droplet is formed.  The TIP TIG wire agitation helps detach and speed up the transfer of the molten weld drops into the fluid weld pool. Without the wire agitation the droplet at the wire tip could grow larger, and the continuous, rapid fed wire  could be driven into the weld causing a disruption. No Manual TIG welder could provide a continuous fed weld wire consistently at the TIG arc plasma sweet spot. The TIP TIG optimum wire placement at the sweet spot in the arc outer plasma periphery, is using an area in the plasma in which minimal plasma energy is utilized for the wire melt, and therefore in contrast to regular DCEN TIG, more of the TIP TIG arc plasma energy can be maintained over the fluid surface of the weld.

TIP TIG Plasma Heat Distribution is different than TIG.  Again note with regular DCEN TIG, the plasma distribution and the intermittent plasma task between   melting the large diameter TIG wire and heating the weld and part surface. The TIP TIG wire agitation and the wire preheat are the defining  difference between TIP TIG and the traditional, manual, DCEN TIG process. The TIP TIG wire  agitation is also the prime difference between  TIP TIG and the Automated Hot Wire TIG process. 

Note: TIP TIG is highly suited as both a Manual and Automated weld process. In contrast, regular DCEN TIG is rarely suited to weld automation, and the Hot Wire TIG process is rarely suited as a manual arc weld process.


With TIP TIG, a complex alloy becomes a simple weld application.

You would think that weld shop evolution would be driven by the  high tech. industries such as aerospace, defense, medical, power and oil.

TIP TIG should be  the logical manual and automated arc weld process of choice for the high tech industries. From welding investment castings in fighter planes or welding super alloys, armor plate, duplex, titanium, hastelloy or high strength steels on submarines and tanks. With many alloy welds  welds, the high tech industries industries often look towards complex, automated weld processes such as the Electron Beam, Laser, Plasma  or the Friction Stir process, to produce high quality welds with minimal influence on the weld Heat Affected Zones, which in many instances, (weld joint design permitting), may also be delivered by the much lower cost, manual or automated  TIP TIG process. 


Think of the manual or automated weld application possibilities.

With nuclear spent fuel containers and engineers are not considering TIP TIG, someone in the office is asleep at the wheel.

Please remember that TIP TIG is both a manual and easily automated weld process. If the TIP TIG manual or automated process is  suitable to the joint design, (the alloy is usually not relevant), remember that in contrast to the sophisticated automated weld processes, if TIP TIG is suited to the weld joint design and thickness, that the TIP TIG weld equipment that will typically costs 5 to 10% of a laser or EB unit, will produce the weld quality desired with minimal weld heat influence on the part weld’s HAZ. 

Note: The easy to use TIP TIG process would not require the special process expertise that comes with a Laser, EB or Friction process. TIP TIG would also have less weld dimension tolerance concerns and less weld fixture requirements than is typically required with the mentioned automated weld processes.


Why would anyone not consider TIP TIG for welding those LNG facilities and vessels?

2019: For more than a decade the use of the TIP TIG process should have been a logical choice  for the LNG industry. No other manual or automated arc process is better suited to weld duplex and stainless  LNG applications. I hope it does not take another 10 years before managers and engineers wake up to the benefits of the easy to use, cost effective process that always provides the highest all position weld quality potential, with lowest heat input. 

 

A moment on Pulsed MIGI have spent over 35 years evaluating the Pulsed MIG process and written hundreds of pages on why so many weld issues occur with this process. After 35 years of pulsed MIG evaluation, the same weld quality issues are occurring especially with steels, alloys and alloy steels  >5 m.  My web site weldreality.com and my weld process control training programs go into extensive details why the use of this process requires weld shop caution on many applications. However the reality is for three plus decades,  pulsed MIG has been  presented by the weld equipment manufactures and distributor sales reps as the greatest thing since sliced bread, of course many weld shops will buy into another crutch for their steel and alloy steel welds.

Without question pulsed MIG provides excellent weld benefits for aluminum welds that benefit from the moderate weld energy attained. In contrast steels and sluggish alloys benefit from “consistent high weld energy”, so the weld shop has the option of pulsed MIG which spends 50% of its time at a low back ground current usually less than 120 amps and the traditional MIG spray mode in which the high energy is relatively constant. 

Pulsed MIG weld Fusion and Porosity: One thing that influences both  Pulsed MIG and Spray weld fusion is the weld deposition rates typically attained with these two weld transfer modes are often too high, and will require fast weld travel rates. The rapid weld speeds and the pulsed MIG weld energy produced on many steel and alloy welds especially on parts > 5, may  produce marginal weld fusion or lack of weld fusion.

Marginal weld fusion in scrap test welds usually means lack of fusion in the part welded

In contrast to pulsed MIG welds, TIP TIG provides a much “higher arc temperature” and “lower deposition” rates that require slower weld speeds than pulsed MIG.  Remember slower weld speeds are helpful in attaining good weld fusion especially with all position welds and welds on sluggish alloys. Also with TIP TIG you have the weld metal agitation which when combined with the higher TIP TIG arc and weld temperatures should enable TIP TIG to always produce superior weld fusion than any pulsed MIG weld. As TIP TIG does not use the reactive gas mixes required by pulsed MIG, TIP TIG with its inert argon and high temp welds, should always enable the lowest weld porosity potential.

If a company is considering manual pulsed MIG for welding submarine high strength steels, the duplex and stainless metals on LNG vessels, or for that matter welding any code quality welds on parts thicker than 5 mm, be warned. Do weld section macros first on scrap of the same metal type and thickness. Apart from the middle of the weld joint where you will often find marginal weld fusion, also make sure you examine the first inch of weld, and any weld tie-ins. There is a good chance you will reveal lack of weld fusion or porosity. That weld defects are not likely to occur with TIP TIG welds made in any weld positions.

BOY YOU HAVE TO LOVE THE AEROSPACE INDUSTRY.

Old weld technology on new space exploration.

As someone who for a short time was involved with weld joint design and weld process decisions on the Moon & Mars Orion Spacecraft, I am well aware that many of the weld joints required in Aerospace, Defense and Power industry are unique, and yes many will justify the use of EB, Laser or Friction Stir.  However lets face it, a good engineer in the high tech industry would be aware of the practical and cost effective weld technology available. And when possible, that engineer should be making practical, cost effective weld process decisions. YAWN.

TIP TIG and dramatic weld Heat Reductions: Few of the engineers that deal with high strength steels and alloys will be aware that in contrast to regular TIG and pulsed MIG, that TIP TIG has the capability not only to meet any weld quality requirements but also provides the ability to reduce traditional TIG and Pulsed MIG weld joules input by approx. 60 to 75%. Proof in TIP TIG video below.

What could the remarkable TIP TIG weld joules reductions do for the parts that your company daily welds?

[] Think about the DCEN TIP TIG low heat and the reduction of stresses that reduce weld crack and weld HAZ potential.
[] Think about the DCEN TIP TIG lowest weld heat and ability to eliminate weld distortion concerns.

[] Think about the DCEN TIP TIG low weld heat that enables the smallest weld HAZ and easily attains the best possible mechanical and corrosion properties.
[] Think about the DCEN TIP TIG low weld heat and producing arc welds with the lowest possible oxidation potential, reducing  weld porosity concerns.
[] Think about the DCEN TIP TIG low weld heat capability,  and the weld shops present use of ASTM and other  specification guidelines for preheat – inter-pass and post heat treatments with  high strength. alloy steels and alloys. The common heat treat recommendations typically used in the global weld industry in 2019 belong to arc weld processes such as MIG – TIG and Flux Cored that on average will put  50% more weld joules  into the welded parts than the DCEN TIP TIG process.


Weld Preheat, Inter-pass or Post Heat may be reduced or eliminated.


With DCEN TIP TIG
, your typical preheat, inter-pass and post heat weld heat recommendations may either be eliminated or dramatically reduced. As you will see in the video below, the weld heat from DCEN TIP TIG is so low, that welding  heat sensitive Titanium can  be done without a gas trailing shield.

2019. The following  SpaceX 300 series, stainless vessel will be the world’s largest,  21st Century spaceship. It’s a pity that  TIP TIG which has been around more than a decade, would likely not have been given the consideration it deserves for some of the required welds. 

It’s also a sad engineering fact that 20 Century arc weld processes, weld specifications and weld procedures are still being used for 21st Century space travel. 

In a few years, Mr. Musk would  like to send humans on a round trip to Mars in his companies giant, 300 series stainless spaceship. It’s understandable that Mr. Musk at his Tesla CA. facility, possibly did not understand the human, arc weld process controls & best weld practice expertise that was and still is required by his MIG and Resistance robot workers, however its been  sad reality  that when welding the parts for his SpaceX vessels, that the SpaceX engineers will like their peers at many of the other aerospace companies, likely will not be aware of the TIP TIG weld application potential. If you worked in a weld shop, you may have heard this.

Come on guys get a grip its time for change.

Questions call me 1 828 337 2695 eastern US time.

Compare TIG and TIP TIG Page 2

In 2019, at the majority of the major global high tech companies, most of the manual, code quality arc welds will be made using the 70 plus year old DCEN TIG, (GTAW) process. And if not using traditional DCEN TIG for their manual welds, the weld shops will likely be using pulsed MIG, SMAW, and the Gas Shielded Flux Cored process. These  arc weld processes will require higher welder skills and always provide inferior weld quality with higher weld heat than DCEN TIP TIG.

For decades the global weld industry has been utilizing arc weld processes, in weld shops that expected weld REWORK.

As most weld shops will be aware, when X-Ray weld quality was required, with the traditional, primary manual arc weld processes that have been utilized  for decades, costly weld rework was the expected norm. This should  no longer be the case when the TIP TIG process is selected.

SHOP ATTITUDES CAN INFLUENCE  WELD QUALITY, WELD  COSTS AND WELD SHOP EVOLUTION:

How weld shop attitudes can also affect weld process evolution & 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?” Welder skills also play an important role in new process acceptance.  Traditional DCEN TIG for example requires the highest welder skills, and in some weld establishments these skills can create a welder diva mentality, whereas some of those TIG  welders may proudly proclaim,  “I am a Nuclear TIG Welder” or “I am a Titanium TIG welder”. TIP TIG takes a few days to learn and it takes weld quality to higher levels ever attained by manual TIG welders.


SO HOW EASY COULD IT BE TO WELD LARGE SCALE  TITANIUM APPLICATIONS?

So when the Army wanted to make lightweight Howitzers out of Titanium, TIP TIG was available and I tried to inform them how this process would simplify the application and would cut  hundreds of millions of dollars of the Howitzer mfg. costs. No one listened. A decade later I doubt if any of the Army personnel involved in weld engineering decisions will be aware of the TIP TIG process, and especially the weld benefits it would bring to any alloys, all high strength steels, investment castings and  armor steels.


TRADITIONAL MANUAL DC TIG OR AUTOMATED HOT – COLD WIRE TIG AND TITANIUM WELDS:

The more complex the alloy, the easier it is to do using the DC TIP TIG process.

IN 2019, MOST WELD SHOP WILL WELD TITANIUM APPLICATIONS USING THE 20 th CENTURY METHODS:  Typically all position, manual or mechanized Titanium TIG welds on parts > 3 mm, such as the  above USA Navy titanium pipe welds, will be carried with DC TIG that provides very low weld deposition rates producing  pipe “fill pass” weld speeds in the 3 to 5 inch/min range. Those multi pass, low DC TIG  weld speeds generate high weld heat, and therefore to minimize the effects of the weld heat oxidation on the titanium welds, there is time required for inter-pass temp. controls, and gas trailing shields have been considered essential for  Titanium pipe welds as indicated.

When alloy welds are made on titanium and the welds are highly sensitive to oxidation, the finished weld color will speak for itself,  and weld porosity will  often be a concern. In contrast to regular DC TIG, depending on the part thickness, TIP TIG manual or automated, titanium  pipe fill pass weld deposition rates will typically be 200 to 400% greater than TIG, enabling  weld fill pass travel rates  typically in the 9 to 25 inch/min rang. Please note also, on most titanium welds on parts over 1/8, inter pass temp is not required and  a gas trailing shield would not be required.

2019..YOU WANT TO VIEW THE WELD CAPABILITY OF TIP TIG A WELD PROCESS THAT ENABLES   BOTH THE HIGHEST POSSIBLE WELD QUALITY AND LOWEST POSSIBLE WELD HEAT?  THEN WATCH DC TIP TIG  WELD TITANIUM. 

The following video is a TIP TIG Titanium weld that in 2019 no Aerospace, Defense, Power or Energy company is capable of making this weld using DC TIG, Pulsed MIG or Hot Wire TIG


“WILL YOU TAKE A MOMENT TO SEE HOW EASY IT CAN BE TO WELD TITANIUM: Welding the above army titanium howitzer or navy titanium pipe would have been simple with TIP TIG.  In 2010, when I was setting the TIP TIG weld parameters for my business partner Tom to weld some Grade 2. Titanium scrap parts, the engineering manager from  the large Philadelphia Titanium fabricator that supplied the test parts, asked why I was not going  to use an argon gas trailing shield to protect the titanium weld and part from  oxidation. I knew something that this engineer did not know.

Though this was the first time titanium would be welded with TIP TIG in North America, I was well aware when welding other heat sensitive alloys of the very low weld heat that I had already been attaining  and that we would not  likely need a gas trailing shield to minimize oxidation and attain the desired titanium weld SILVER color. By the way as we were just setting our TIP TIG weld shop at this time and we had nothing that would correctly clean the  titanium parts  and  they still had forming / cutting contaminates on, (the  reason for the weld  fumes).  

WHY TIP TIG DID NOT NEED A GAS TRAILING SHIELD. At a DC TIG weld speed of approx 3 inch/min with one weld start and stop for a new wire length, the time to weld the above eighteen inch long,  1/4 thick titanium  part with TIG would be approx 6 minutes. In contrast  the time to weld the titanium part with  TIP TIG travelling at 24 inch/min as shown on the video, was 44 seconds.  The weld heat  with DC. TIG  39,600 J/inch, the weld heat with DC. TIP TIG,  5.550 J/inch. Its the higher weld travel speeds attainable with  DC TIP TIG that will always on most applications > 1.6 mm enable a remarkable weld energy difference between  traditional DC TIG and TIP TIG. Keep in mind also that  even tho. DC. Pulsed MIG could weld a little faster than TIP TIG, that DC.Pulsed MIG uses Reverse Polarity which  concentrates the weld heat in the MIG plasma and this greatly influences the high weld and part HAZ heat you get with any Reverse Polarity MIG

Remember also when dealing with weld heat sensitive alloys and considering MIG, that  MIG provides higher part heat and also requires reactive gases such as CO2 or Oxy. which influence, oxidation and  porosity on any application. TIP TIG only requires argon and should never require helium.  The TIP TIG weld benefits that apply to this titanium weld, also applies to any alloy or steel application you want to weld with TIP TIG.

“WELDERS WANTED TO WELD  TITANIUM VESSELS, MINIMUM WELDER SKILLS REQUIRED”.  TIP TIG is easy to use,  just like MIG, with TIP TIG you can have one or two hands on the torch just point and move and no  foot control required. From a root pass to any position weld, TIP TIG  makes all position welds an easy task.

Dont forget that weld Costs are of course influenced by the required Welder Skills:  Apart from the weld deposition rates attained and weld rework required, weld costs are also influenced by the required welder skills. Weld shops take note, all of the traditional arc weld processes such as traditional DCEN TIG, Pulsed MIG, Flux Cored or the SMAW process, require higher all position welder skills than required with TIP TIG. Also as we are all aware when hiring TIG welders, the welder skill requirements will influence the hourly labor costs, and also the manual welder skill differences will affect weld defects.

Note. Every business is aware that  in 2019, all position skilled weld personnel are in short supply. With TIP TIG not only do you enable the highest all position weld quality, this also is a process that requires the lowest all position welder skills. 


With TIP TIG, in contrast to TIG, the weld application size and thickness are no longer that relevant.
 

Weld quality and Process influence:  Weld quality is not only influenced by manual welders skills, but also by the weld process selected. Apart from what influence a manual welder has on the welds being produced, the weld process selected will also influence the weld quality attained. Most weld shops are aware of the potential for lack of weld fusion and porosity with the Pulsed MIG process. And weld shops will expect trapped slag and porosity from the Flux cored  or SMAW process.  The high welder skills as required by traditional DCEN TIG, will also influence the weld quality attained, and the slow TIG weld speeds will influence the weld heat and hourly weld labor costs.After assisting over 1000 companies in 13 countries with their weld issues. From my perspective, it  does not matter if someone works in the front office, the QA office or on the weld shop floor, the first management and 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 have both simplified and condensed.  If you can give any of these process subjects 15 – 20 hours of your time, and pay the cost of a good dinner for four, become an expert. My Training / Self teaching resources are available here. 

DCEN TIP TIG – Advanced AC TIG – Robot  & Manual MIG – FCAW, Weld Process Controls – Best Weld Practice Expertise  here.

Its  2019,  and the majority of prime  Aerospace, Defense and Nuclear companies and their contractors have for more than a decade been using the outdated arc weld processes, outdated weld specifications and procedures, and not being aware of  the arc weld process controls and best weld practices required for weld process optimization.

 

My business partner Tom and I introduced TIP TIG to Australia, and the Australian Government Navy Department found out how easy it was with TIP TIG welds for their workers to pass the Navy destructive, explosive hull weld tests. 

Sept 2018. AUSSIES NOW LEAD THE WAY IN SUBMARINE  WELD  REPAIR TECHNOLOGY:   

While the world’s prime defense contractors  are usually stuck in an arc weld time warp, ASC Pty. Ltd, an Australian Government business owned ship builder has proven that the TIP TIG process  attains astounding weld quality and cost results on it’s  Submarine Hull Weld Tests. 

Ed Craig..2018. Collins Sub… The Australian Government company ASC approves TIP TIG as it’s arc weld process of choice for Submarine Hull build / repairs. The following comments are from the ASC Chief Executive Officer is Mr. Stuart Whiley….”To evaluate and approve  the TIP TIG process, ASC used an explosive weld test on Submarine Hull, High Strength Steel Plate”. 

To gain Commonwealth  engineering approval, ASC-welded test specimens of the hull steel had to pass repeated explosive bulge tests at a facility in Victoria. Not only did TIP TIG prove to be a superior process to the DCEN TIG process, the TIP TIG process solved a major problem for the Aussies, as this country has a concern with finding the skilled TIG welders to work on submarines.  TIP TIG quickly revealed it’s much easier to use than TIG,  it provides superior weld quality and mechanical properties and has the potential to lower reduce the TIG weld costs in the range of 200 to 400%.

TIP TIG was brought to Australia in 2009 – 2010 by myself,  and my business partner Tom  O’Malley, (both formerly TIP TIG USA owners). We established the Australian TIP TIG distributors and TIP TIG USA trained the Ausy personnel in the use of this unique weld process. In 2019  the Ausy government placed an order for 50 billion dollars to purchase submarines, and I know with TIP TIG that they will now feel confident that when it comes to doing future sub weld repairs it will be a simple task with TIP TIG. 

In conclusion from Em:  The following are a few  of the  things that would help any shipyard working on Merchant or Navy contracts.
[] Have the ability to take less advice from weld sales personnel.
[] Do not accept any welder training program that produces welders who  “play around” with weld controls.
[] Those that make make weld decisions, ensure you have the expertise required for weld process ownership.
[] Where  appropriate for all position code quality welds, consider TIP TIG.
[] For MIG – Flux Cored and TIP TIG welds, implement Weld Process Controls and Best Weld Practice Training for  welders, inspectors  and involved front office personnel.
[
] Change the QA weld  inspection approach from defense to offence so inspection personnel , learn how to prevent rather than simply reveal weld defects. 

More data on on the dramatic weld cost issues in Ship and Sub building in my weld programs at www.weldreality.com.

 If you want to discuss  TIP TIG call me eastern time U.S. 828 337 2695.  If you want Arc Weld Process Controls and Best Weld Practice Self Teaching  / Training Programs that are necessary for process optimization and ownership, check the following link.

Em’s TIP TIG, or MIG and Flux cored  Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs.


When using traditional DCEN TIG and welding a complex, heat sensitive alloy such as Titanium parts > 1/8, the weld shop will be aware of the sensitivity of the titanium to weld heat and the oxidation formation potential. This is an oxidation revealed when welding in the weld color, and that color will often be the subject of many QA personnel decisions that often result in  costly titanium part rejects. To prevent the oxidation that occurs with the weld solidification and cooling  of the titanium welds, a cumbersome inert gas trailing shield will be attached to the manual TIG welder torch, who typically will be welding at slow weld speeds that are the primary cause of the weld heat generated.

In contrast, the use of  DCEN TIP TIG on the > 1/8  titanium parts, would reveal that not only will TIP TIG not require the gas trailing shield,  it will always create the highest possible arc weld quality with the lowest possible weld heat.  As for the welder working with TIP TIG they will not require the typical welder skills of feeding a weld wire and will not require a foot control. The bottom line is most titanium applications can be welded with two simple weld settings using the same weld practices as they would use on simple steel or stainless applications.

Take a moment with the TIP TIG video below. Welding  a complex titanium alloy without using a gas trailing shield. 

When I set the TIP TIG data for a first time attempt on these titanium vessel parts, I knew as I set the weld data for Tom to weld the titanium, that we would not need to use  a gas trail shield.This I believe was the first time in North America that titanium was welded successfully without the use of a gas trail shield.

Em’s TIP TIG, or MIG and Flux cored  Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs.a

 

 

The common global lack of engineering and management focus on the requirements for arc weld process ownership that would enable weld process quality – productivity optimization, is why we have a “play around with the weld controls” industry. An industry that too often relies on a weld salesman for weld advice, an individual that who has likely never ran a weld shop.

After evaluating and simplifying weld process for 50 years, what really frustrates me is the so called high tech industries such as Defence, Aerospace, Nuclear and Oil are typically the most entrenched in the use of 1950s arc weld processes, and also you would note that the weld procedures use in the 1970s – 1980s period are little different from those used today. This Rip Van Winkle approach to welding is especially evident  in  Aerospace, Oil, Nat Gas, Nuclear, and likely in every global Naval Ship Building yards. Ed Craig. weldreality.com

With Ships, Submarines and Offshore Oil Rig construction facilities, the common manual arc weld processes such as SMAW, Flux Cored, MIG and GTAW have been used for many decades. While these processes are effective for joining metals, none of these arc weld processes are ideal from a  weld quality, weld part properties or from a weld cost perspective.

Each of the common, long established arc weld processes has more than one Achilles heel that affects the weld quality or productivity,  and their has always been room for process improvement. We do see those improvements with MIG – TIG arc weld processes for  aluminum, yet for decades we have seen mostly useless electronic bells and whistles for steels and alloy welds.

However just because many weld shops are stuck in a 1960’s time warp does not mean, that the front office engineers, managers  and supervisors responsible for their companies arc welds, while lacking process expertise, should not at least  have an open mind to any weld process change that can prove in a demo in a matter of minutes, both dramatic weld quality and weld cost savings.

Many who work in our weld industry will be aware, that of the common attitude found in the “play around” with the MIG and FCAW weld controls weld shops, will be “why change the way we have always done it”. 

Traditional TIG, slow, highest skill requirements, high weld heat, yet entrenched throughout high tech industries that lack weld Management Ownership Expertise.


When the highest “manual arc weld quality”  has been desired to weld steels, alloy stls. and alloys, the DCEN. GTAW. (TIG) process has been the weld process of choice. As any good designer, weld manager or engineer involved with arc welds should appreciate, even that 70 year old, unchanged DCEN TIG process used in their weld shop, has to eventually evolve.

Traditional TIG first used in the 1940s, and  with with DCEN steel and alloy TIG welds, there’s little to differentiate a TIG weld made in 1958 or a TIG weld made in 2018. 

2018… It’s taken approx.  70 years, but for those front office personnel asleep at their computers, or constantly in the weld shop fireman mode, please note the evolution of the DCEN TIG process arrived about a decade ago.

TIP TIG. One hand, and in this demo the Westinghouse welder depositing approx. 400% more weld than any
Westinghouse pipe welder.


The above ten year old process is called TIP TIG. It was  invented by Plasch. Austria. I found TIP TIG in a visit to Scotland around 2008. I only needed 15 minutes with this process to know I had to get it to N.America. I found a business partner, Tom O’Malley who had more than the $50 I had in the bank. We quickly formed a U.S. company called TIP TIG U.S.A. Tom and I then introduced this process to both North America and Australia. TIP TIG is both a  unique Manual Semi-Automated process and also a process  highly suited to  Automated and Robot welds. TIP TIG has none of the limitations of the Hot Wire and Cold Wire TIG processes. See my blog on Hot Wire TIG. 

Single pass untouched TIP TIG steel fillet, note weld color and small HAZ from low weld heat. You would go to sleep with the slow weld speed that would be done doing a steel or stainless TIG weld like this. Not with TIP TIG that  300 –  400% increase in the TIG deposition means much faster TIG weld travel rates. TIP TIG opens up the opportunity to now use manual or automated TIG welds on any thickness. Think of those Stainless, Inconel, Duplex, Hastelloy,  Titanium and high strength steel weld application. By the way as the weld heat input is so low, TIP TIG would not require a gas trailing shield if this was a TITANIUM  application.


WHAT’S THE SENSE OF BEING PROUD TO BE PART OF A HIGH TECH DEFENSE OR AEROSPACE COMPANY LIKE BOEING, SPACEX,  EXON OR NORTHRUP, AND FIND OUT YOUR  WELD DEPARTMENT STILL IN 2018 IS CLINGING TO A 70 YEAR OLD WELD PROCESS SUCH AS DCEN TIG.  

When the traditional DCEN TIG process evolved into TIP TIG, in contrast to DCEN. TIG, the TIP TIG enabled numerous weld / part benefits on all steels, alloy steels and alloy weld applications:

 IF IT’S TO EASY TO PRODUCE DEFECT FREE WELDS, IT MUST BE TIP TIG.

Now who in 2018 would want to produce the highest possible weld quality that ensures no weld rework? Who would would want to weld with a process that alway enables the lowest possible weld heat? Then again, why would anyone want to use a process that dramatically reduces the TIG welder skills? And lets face it, you would have to be an idiot to choose a process that that each hour does 200 to 400% more TIG weld. And don’t get me going on why you would want to use a process that delivers the lowest possible weld fumes.

  • [] TIP TIG provides far superior weld quality with a dramatic reduction in lack of weld fusion and weld porosity defects.|
  • [] TIP TIG provides the lowest possible arc weld heat on any application, with the increase in weld quality this enables superior part & weld metallurgical properties.
  • [] TIP TIG in contrast to both DCEN TIG and also to the Pulsed MIG process, enables  a dramatic reduction in “all position” welder skill requirements.
  • [] Also in contrast to DCEN TIG, the TIP TIG process typically enables a  200 – 400% increase in hourly weld deposition with dramatic reductions in the hourly TIG labor costs.
  • [] As TIP TIG welds are done so much quicker weld gas costs are dramatically reduced and the use of lower cost spools of 0.035 – to 1/16 MIG wire reduces the TIG weld wire costs.
  • [] Other benefits from TIP TIG are the capability with DCEN polarity and higher weld speeds to always  enable the least weld distortion, and create welds with the lowest possible weld fumes.By the way, with it’s latest Inverter TIG equipment,  Miller proudly announces it can speed your DCEN TIG welds by 17%. So that TIG weld in which  your welder travels at 3  inch/min, will now with Millers latest Inverter allow the welder to speed up be 3.5 inch/min. In contrast to the electronic advances in today’s Inverter TIG power sources,  TIP TIG will typically enables 200 to 400% increase in TIG weld speeds.Weld shop managers, engineers and supervisors you might want to wake up, as the benefits attained by TIP TIG are not the nickel and dime, hard to measure benefits that are usually enabled with the latest electronic inverter DCEN TIG and  also Pulsed MIG equipment changes.The beneficial process  attributes from the TIP TIG process enable game changing weld quality / production benefits that can  dramatically impact any weld shop’s weld application capability and weld quality and cost bottom line.

I  JUST SHAKE MY HEAD WHEN I READ ABOUT WELD SHOP MANAGERS OR CORPORATE EXECUTIVES LAMENTING ON THE SHORTAGE OF SKILLED WELDERS….Excuse me, I have to yawn….

WHILE IT MAY TAKE A WELDER A  FEW YEARS TO ATTAIN THE SKILLS REQUIRED TO DCEN TIG WELD ON ANY ALL POSITION CODE QUALITY APPLICATION. IT WOULD TAKE SOMEONE WHO HAS NEVER WELDED USING THE TRAINING I PROVIDE, LESS THAN A MONTH.

By the way if you need to hire MIG or flux cored welders that can meet any code welder qualification requirements for any industry , my unique process controls – best practice training  programs enable anyone who has never welded approx. 10 days  to meet those requirements, and these welders will not be “playing around” with their weld controls. 

2018.  High tech ships,  and low tech weld technology. 


Part of a 2018 article from B Peniston. Deputy Editor Defense  One he reports on what was being stated by J Geurts the Assistant Navy Secretary for research, development and acquisition. Geurts spoke at a Defense One Tech Summit. The following summarizes  a primary point of the seminar…

Geurts.. “The US Navy can’t build our future planned fleet unless it finds ways to dramatically reduce it’s ship / submarine build and repair costs”.

“For the Navy and the Marine Corps, if we can’t solve and fundamentally drive some of the costs out of our ships over the long term, especially with the construction, repair, and engineering costs,  our  U.S. industrial base will not  attain the 355-ship fleet goal required by our national strategy.  Please remember that it was only a few years ago,  that the USA had the world’s most capable and cost effective shipyards.

———————————————————————– 2018…Today in North America, when you examine  our general lack of industry management & engineering weld process ownership and the unnecessary daily,  manufacturing and construction issues, (Ed’s weldreality.com, extensive info on this subject) we need to go way beyond labor costs as the root cause of our frequent jobs demise. Perhaps we could spend a little more effort to examine our management, engineering and fabrication expertise and capability.   New Sub design, will it be built with old inferior weld Technology.

The Navy and of course the taxpayers are ready to purchase a new class of submarines and invest over 200 billion dollars. At the same time the Navy expresses it’s concerns about Submarine  fabrication delivery times, and reducing the sub. fab. and weld costs. As its done for decades the Navy calls out for ship yard improvements and  CHANGE,  but the Navy as the customer seems to lack the will for process ownership and therefore the   will to demand CHANGE.


Around  2009 to  2011, I called many high ranking Naval officials and asked them would they have a interest in dramatically increasing weld quality and decreasing both  their flux cored weld quality and productivity issues through weld process controls, and also viewing the new TIP TIG  process. Not one of the Navy executives indicated an interest. The Navy or the weld industry few want the responsibility for weld process Ownership.

WHILE THE USA  AND CANADIAN  NAVY TALK THE WELD / FAB. WOES  TALK.  COUNTRIES SUCH AS CHINA AND EVEN AUSTRALIA ARE EMBRACING NEW FAB. AND WELD TECHNOLOGY, AND THEREFORE YOU COULD SAY THEY WALKING THE WALK. 

As the U.S. Navy is aware, China as it does with any important technology, will embrace or copy it, and aggressively work to implement  it to become a global leader in defence projects and especially in Naval ship – submarine building. So maybe I should not have been surprised  that when we first opened our U.S. TIP TIG facility around 2009,  ironically our first  facility was located in the “Philadelphia Navy Yard”, that after attending one of my TIP TIG seminars,  our first large prime customer was CNOOC from China. CNOOC is the third largest “offshore” Oil company in China, they focus on the exploration & development of offshore Oil and Gas. CNOOC sent a group of their engineers  to my workshop then to our weld shop to view and test TIP TIG process.
One of the most difficult weld challenges is Sub Sea Pipe Welds

Offshore pipe laying barge can create great weld challenge. Imagine renting a ship to lay offshore sub-sea pipe,  that ship occurs a daily approx. cost of $255,000.00 a day.. Each 8 to 10 inch pipe start & end had to be ID automated clad weld with Inconel. Then after edge prep.  the pipe OD end joints had to be manually welded with two welders and X-rayed, there was   no tolerance for weld rework. Imagine  the cost consequences from  a pause in that pipe clad and weld joint weld production. Weld rework was for other people and the Chinese were lucky to find TIP TIG in  the USA.

CNOOC had a COMBINED  Inconel – alloyed steel  pipe weld and clad application that required the highest degree of weld challenge and had dramatic weld cost consequences if weld rework was required. Part of TIP TIG ID clad application below.

 Inconel multilayer, multi-pass welds on end of the sub sea pipe. With excess weld heat buildup you still have to control the weld freeze characteristics. No interpass temps or weld rework allowed. By the way the weld times were critical.. It was simple with TIP TIG and even the Chinese who had tried all other available TIG and pulsed MIG processes were impressed.

    
These  inconel clad welds  could only be a achieved  TIP TIG. 

Note: The multi-pass, multi-layer weld solidification uniformity, this is the ultimate in difficult clad weld control especially with no interpass weld control.

For their pipe welds that lay on the ocean floor, CNOOC traveled the globe and tried both the world’s best pulsed MIG process from companies like Fronius and the most sophisticated Advanced, pulsed Hot Wire TIG technology from Europe.  As the months passed, they found no weld process that capable of meeting either their weld or clad needs. A prime concern was the short weld times demanded, controlling the weld heat with the ID pipe multipass – multilayer inconel clad welds. and having no weld rework on the pipe weld joints.

The Chinese stayed in our TIP TIG weld shop for a week, working 12 hour days, and whatever the TIP TIG manual and automated weld and clad tests that they provided, passed with flying colors. 

Once the pipe clad ID welds on the barge were complete,  the pipes had to be edge prepped and OD welded. The all position, manual  TIP TIG pipe welds had to  meet the most stringent weld code requirements, weld rework was not acceptable  and the welds made in the shortest possible weld times. 

Each TIP TIG welder you see below required less welder skills than a regular TIG welder. Each of the TIP TIG  welders was producing approx. 300%  more weld each hour than any DCEN TIG manual welder could produce.  Also lets not forget the higher weld quality than possible with TIG, and  the lowest possible weld heat and lowest possible weld fumes. 

 The quicker the OD pipe welds were made and NDT reviewed and accepted, the quicker that pipe would end up on the ocean floor.  With the daily pipe production requirements and massive ship overhead costs, weld speed was critical and weld defects were simply not an option, on the numerous pipes that were fed daily onto the ocean floor.


EVEN SOMEONE IN THE WELD SHOP FRONT OFFICE,  THAT LACKS PROCESS OWNERSHIP EXPERTISE AND EVERY DAY SPENDS THEIR TIME IN THE FIREMAN ROLE, SHOULD BE ABLE TO FIGURE OUT  THE IMPORTANCE AND BENEFITS OF A WELD PROCESS SUCH AS TIP TIG THAT DRAMATICALLY REDUCES TIG WELDER SKILLS, LOWERS LABOR COSTS AND IMPROVES THE WELD QUALITY.
WE CANT GET WELDERS THEY LAMENT, THAT’S BECAUSE YOU DON’T KNOW HOW TO CORRECTLY TRAIN WELDERS,  SAID I.Ed Craig.. For many years it’s been difficult for many countries to get the experienced TIG welders, especially when large scale weld projects requiring code quality weld work was required. TIP TIG has dramatically reduced those TIG welder skills and the TIG training requirements for  DCEN TIG welders. TIP TIG has also reduced TIG hourly labor costs typically in the range of  60 to 75%.  Any of the above statements can be proven in about 30 minutes at your facility. Contact  E. Craig  ecraig@weldreality.com.  If you want a TIP TIG, flux cored MIG and robot MIG workshop, seminar or  training at your organization, give me a call. 828 337 2695.  If you want to do it yourself with the best possible TIP TIG, Gas Shielded Flux Cored, Manual MIG or Robot Mig and  Self Teaching and Process Controls – Best Weld Practice Resources,  click here.Most of the shipyards that build Aircraft Carriers or Navy Frigates will  annually create millions of dollars of unnecessary Flux Cored weld rework, the reason is simple,there are few in the front offices of this important  industry that understand the importance and requirements  of  weld  process ownership, and have the ability to implement the weld process controls – best weld practices that will minimize the opportunity for weld defects, and optimize weld production.  You would think that those designing and  building Submarines should have every incentive to change to a process such as TIP TIG, a process that enables both dramatic weld quality improvements and weld cost reductions. However there is a reason why my site is called WeldReality and I know that many of  you will likely understand why those that shy away from weld process ownership, will not likely be first in line to encourage a weld process change. Ed Craig… I sometimes wonder if reducing  Navy ship fabrication / welding  costs is possibly not a great incentive to  the contractors that deal with the lucrative, large Navy contracts. If that’s the case the Navy should drive the train, however from my perspective it sometimes seems  that the USA Navy top brass like to “talk the cost cutting  talk, but are  not prepared to walk the cost cutting walk”  required to drive the design, fabrication and weld changes necessary to attain  the desired  ship and submarine build cost reductions.EVERYONE THAT CALLS THEM-SELF A WELD DEPARTMENT MANAGER OR RESPONSIBLE ENGINEER OR SUPERVISOR, SHOULD BE AWARE THAT POSITIVE WELD CHANGE IS NOT  DRIVEN BY FRONT OFFICE WISHFUL THINKING AND DEFINITELY NOT  FROM THOSE THAT LACK THE ABILITY TO OWN THE PROCESSES IMPORTANT TO THEIR COMPANY. E Craig.E. Craig EMail  ecraig@weldreality.com.  If you want a TIP TIG, flux cored. MIG and Robot MIG seminar or training at your organization, give me a call. 828 337 2695.  If you want to do it your your self, the best possible self teaching, process controls – weld data and best weld practice resource, are here.
The following is an example of the Australian approach to driving weld change with   Submarines.  

 Ed Craig. Sept 2018. AUSIES LEAD THE WAY, NOT AT THIS TIME IN BUILDING SUBS, BUT IN SUB ARC WELD  REPAIR TECHNOLOGY:   While the world’s prime defense contractors  are too often stuck in an arc weld time warp, ASC Pty. Ltd, an Australian Government business owned ship builder has proven that the TIP TIG process  attains astounding weld quality and cost results on it’s  Submarine Hull Weld Tests. 

Ed Craig..2018. Collins Sub… Australian Government company ASC approves TIP TIG as it’s arc weld process of choice for Submarine Hull build / repairs. Not only did TIP TIG prove to be a superior process to DCEN TIG, the TIP TIG process solved a major problem for the aussies, as this country has a concern with finding the necessary skilled TIG welders to work on submarines.  TIP TIG quickly revealed it’s much easier to use than TIG,  and has the potential to lower the TIG welder requirements in the range of 200 to 400%.


Ed Craig…TIP TIG is a process invented in Austria by Plasch. TIP TIG was brought to Australia in 2009 – 2010 by myself,  and my business partner Tom  O’Malley, (both formerly TIP TIG USA owners). Tom and I also set up Australian TIP TIG distributors and TIP TIG USA trained the Ausy personnel in the use of this unique weld process.

Comments from the ASC Chief Executive Officer is Mr. Stuart Whiley.

Whiley…To evaluate and approve  the TIP TIG process, ASC used an explosive weld test on Submarine Hull, High Strength Steel Plate. To gain Commonwealth / engineering approval, ASC-welded test specimens of the hull steel had to pass repeated explosive bulge tests at a facility in Victoria.

TIP TIG ROOT: Still walk the cup, no wire feed no foot control, then one more wire feed and amp change for all the pipe fill passes. 

Whiley…The weld tests involved a one square meter specimen of Collins Class Hull steel, made up of two sections welded together by TIP TIG. The weld test specimen was repeatedly blown up until the “bulge” in the steel produced a thinning of the hull. 

The last thing you would want to worry about on any sub, is the welds.

Whiley.. The Hull test specimen thinning continues to a certain specified percent. The tests were conducted with the specimens held at temperatures   significantly below zero degrees, simulating the most demanding under-sea conditions. 

Whiley…Careful examination of the TIP TIG welds showed that cracks did not grow or break through, successfully passing this destructive weld  test.  The successful explosive tests demonstrate ASC’s continued expertise in submarine hull fabrication and welding capability. “Proving this advanced application of TIP-TIG welding for the high tensile, low carbon steel used in the Collins Class submarine pressure hulls means we will achieve even higher quality and reliability in our future work on Australia’s fleet of Collins Class submarines,” Whiley said.

Whiley…The new TIP TIG process will be introduced for the re-welding of HMAS Waller’s hull in its current full cycle docking in Osborne, SA. The news follows the recent announcement that ASC is the first Australian defense company to receive the international corporate certification for excellence in procurement by the Chartered Institute of Procurement and Supply (CIPS).


Ed Craig…AS TIP TIG IS EASY TO USE, PERSONNEL WHO HAVE NEVER WELDED CAN WITHIN A MONTH WITH THE PROPER TRAINING PROGRAM I PROVIDE, LEARN TO ATTAIN THE HIGHEST POSSIBLE,  ALL POSITION CODE QUALITY WELDS WITH ONLY A FEW WEEKS TRAINING.

Whiley… This achievement will guide our future work in procurement — a critical role as Australia’s largest locally owned defense prime contractor, supporting the Government’s Naval Shipbuilding Plan.”  ASC built and maintains the Collins Class submarine fleet, employing more than 1,200 submarine personnel in SA and WA. 

Ed Craig… AN IMPORTANT PROCESS THAT’S SIMPLE TO OPERATE AND A PROCESS THAT DRAMATICALLY CAN REDUCE WELD LABOR COSTS ARE TWO KEY ELEMENTS THAT ENABLE COMPANIES TO SUCCESSFULLY  BID ON MANY DIFFERENT WELD CONTRACTS.

Ed Note:  On the subject of arc weld processes and weld defect potential. It’s very difficult to generate weld defects with the TIP TIG manual or automated  process, the reason is TIP TIG  in contrast to other arc weld processes provides the highest possible arc energy and weld fluidity, always with the lowest weld heat input.

Ed Craig …In contrast to TIP TIG,  irrespective of the welder skills, the Pulsed MIG – Regular TIG & the Gas Shielded Flux Cored process have inherent process issues  that can contribute to weld defects. At this site and in my process controls – best weld practice training programs, you not only learn to optimize the common arc  processes but became aware of all the variables that influence weld defects

Ed Craig…Apart from the welder’s skills, the effects of the  process & consumables selected, the lack of management process ownership, and the lack of weld process control & best weld practice expertise / training  are also the prime root causes for the formation of weld defects. 

 E. Craig Oct 2018. ecraig@weldreality.com.  If you want a TIP TIG flux core or MIG seminar or training program at your organization, give me a call. 828 337 2695.  If you want to do it yourself with these arc weld processes, the self teaching / training  process controls – best weld practice resource is here.

The above TIP TIG weld was made on scrap titanium parts that were dirty and not cleaned before weld, (smoke from cutting lubricants still on parts).  Note that  No Gas Trailing Shield was used. Note the fast TIP TIG weld speed for this 5 – 6 mm weld. Also and most important, take a look at the finished, acceptable SILVER weld color which shows the weld heat was so low that no detrimental titanium weld oxidation took place. Imagine this high quality, low weld heat on your alloys or high strength heat sensitive welds.


Concerned 
about weld distortion and the cost
consequences of weld rework revealed by NDT? 

Take a moment, which weld process would you select? The the weld shop wanted both the highest API code weld quality, (no weld rework)  and the lowest weld heat to minimize weld distortion that affects the flange placement. TIP TIG was selected.


Reminder on a few of the TIP TIG weld benefits: Reduced all position welder skills  – reduced weld defects – reduced weld distortion – superior mechanical and corrosion properties – the lowest possible weld fumes.

Managers and engineers involved with welding alloys and high strength steels should be aware that  TIP TIG not only reduces the welder skills, it also dramatically reduces the weld defect potential and enable the highest possible weld properties with the lowest possible weld stresses and distortion. 

Finally, attaining all position, code quality welds that should not require weld rework  is a simple task with TIP TIG. Also any TIG welder that occasionally feels the twinges of aching finger or leg weld joints, should appreciate the TIP TIG weld benefits obtained from not having to manually feed a TIG weld wire through their fingers, and being able to use one or two hands to control their weld torch. And lets not forget no leg work required as no foot amp control required.

2019. For seven  decades, pipe welds were never this simple. If you can lean on a pipe, move your hands in a controlled manner with TIP TIG you will make a good pipe welder.

So what do you think is unusual in the above TIP TIG, P91 pipe weld  application? Apart from the use of one hand, no foot control, no weld spatter, no weld smoke, pipe welder skills reduced and each hour the three to four hundred percent increase in the TIG weld deposition being produced for the weld shop.

P91 TIP TIG weld from first time user, (above video) and
of course NDT 
revealed defect frees.

First time TIP TIG user, X-Ray defect free. You should see what he will do with a few more hours with this process


What you don’t see with the above TIP TIG pipe weld is the best possible weld fusion and lowest weld porosity potential is attained. What you also don’t also see is always the lowest possible distortion and lowest possible weld  stresses. What you also don’t see is the  best possible metallurgical results. You cannot attain the same weld results with regular TIG or Pulsed MIG, and it takes a less than one hour to demonstrate the results.

Note: As all position TIP TIG welds are easy to do, the weld position presented is not that relevant which means with many of your parts less positioning of the parts.

Also on most parts welded > 1.6 mm, the weld application, steels and alloy metal types are not that relevant. And remember with TIP TIG in the weld shop, it does not matter if the welds are either manual or automated. 

A  60  MINUTE TIP TIG DEMO, NO SALES CHAT, & IT’S EASY TO PROVE THE NUMEROUS WELD CLAIMS AT THIS SITE:

As below, a company can spend money on fancy TIG welder jackets, helmets  gloves, yet in this weld shop the welders will still be using in 2019, a 70 year TIG process which takes 3 times longer to do the TIG welds. Using a  process that provides inferior weld quality and higher weld heat and costs than attained with the TIP TIG process.

DCEN TIG changed little in 70 years.

Manual or Automated weld, it’s all the same with TIP TIG. While traditional DCEN TIG is not suited as a Manual, Semi-automated weld process, and it also makes for a poor fully automated TIG process. And also lets not forget that the Automated Hot Wire TIG process is not considered  practical as a Manual TIG weld process. 

In contrast, the TIP TIG process is ideally suited both as a Manual, Semi-automated process, and an easy to use fully Automated arc weld process. As TIP TIG provides respectable weld deposition rates it should be given consideration instead of Pulsed MIG as TIP TIG will produce far superior weld quality with much smaller weld HAZ that will always enable superior mechanical properties, less distortion and stresses.

Question.  So why can’t  the weld shop just attach any old  MIG wire feeder to a TIG torch and make the regular, 70 year old  DCEN TIG process into a Manual Semi-Automated TIG process? 

Answer.
A prime issue for decades with both the traditional manual DCEN TIG and also the Automated DCEN Hot Wire TIG process, is that they are both have wire feed restriction issues and both are  arc length sensitive.

Restrictions of the manual DCEN TIG & weld heat.
[1] The lack of ability with regular TIG, to manually feed a small diameter wire typically above one pound/hr into a rapid freeze weld usually results in welds with very slow weld speeds that with the high TIG arc temperatures, will  often result in  high weld heat. Remember it’s the slow weld speeds and high TIG arc temp. weld heat will often affect the part distortion, weld cracks, weld and part stresses, and the metallurgical properties.
 

[2] Plasm Restrictions and arc length sensitivity.  DCEN TIG arc length sensitivity is influenced by the amount of current and voltage used, also by the TIG arc plasma energy  that’s delivered directly to the weld surface.

The traditional DCEN TIG plasma energy is influenced by its function of melting a large TIG  wire  and the wire placement at the leading edge of the arc plasma. This  large wire placement and melt requirement intermittently deprives the TIG pool of a good portion of the plasma energy from the weld pool surface that can result in a small fluid, fast freeze weld pool that’s sensitive to electron flow disruptions. (arc length sensitivity).   

In contrast, TIP TIG reduces the TIG fast freeze weld effects and arc length sensitivity by the following:  The use of small diameter weld wires, and increased deposition rates that enable higher amps and volts to be used.

TIP TIG’s consistent weld wire placement at the plasma outer periphery  does not deprive the plasma energy from the weld surface.
The TIP TIG wire is angled to the outer periphery of the plasma. With the smaller diameter TIP TIG wire, there is sufficient energy in the plasma periphery to melt the wire  and uninterrupted, plasma energy on the TIP TIG weld surface is part of what makes TIP TIG unique. (The TIP TIG wire placement and small weld drops takes minimal energy from the TIP TIG arc plasma).

TIP TIG’s wire melt at the arc plasma periphery enables most  of the TIP TIG plasma heat to react on the surface of the weld part, this not only assists with electron flow that reduces arc length sensitivity, it also enables increased weld fusion and lower weld porosity. 

TIP TIG’s patented agitation of the weld wire not only assists in the small. rapid droplet transfer from the wire tip. The agitated drops also result in a slight stirring action of the fluid pool. Any agitation of molten metal  should slightly slow down the weld solidification times, an action that assists in electron flow so it helps reduce arc length sensitivity concerns, and assists in weld fusion and weld porosity reduction.

TIP TIG is a Manual or Automated arc process. The above unique DCEN TIP TIG arc plasma attributes combine to allow for a weld that in contrast to DCEN TIG, will provide much higher weld travel rates, a dramatic reduction in weld heat,  and the increased arc energy enables slower weld pool solidification and improved electron transfer stability. These benefits enable the TIP TIG process 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 reviewing the TIP TIG process for the last decade.  This site is copyright protected and this information is not printed elsewhere. If you want to use it, please at least require my permission

That DCEN TIG Arc Length Sensitivity (ALS)  has Cost Consequences. ALS can cause arc / weld outages and is one reason why the automated Hot Wire DCEN TIG process, will depending on the weld application, often require costly  Automated Arc Length Control (ALC) equipment. However as  you see below with a common stainless tank welds. Arc Length Control equipment is not a requirement with Automated or Robot TIP TIG welds.

Below: TIP TIG attached to low cost automated carriage. The multi-pass  stainless TIP TIG welds are being made without the usual  TIG “arc length sensitivity concerns” that would occur with HW TIG.


No Arc Length Sensitivity issues with automated TIP TIG.

TIP TIG for the root and TIP TIG for the fill passes. No matter the weld application size or thickness, if you want the highest possible manual or automated weld quality, with the automation you can get out a carriage, a  rotating table, or utilize a robot. 


I DOUBT IN THE 21st CENTURY THAT THERE WILL BE ANY  OTHER ARC WELD PROCESS THAT CAN DELIVER HIGHER MANUAL OR AUTOMATED WELD QUALITY: Costly NDT will be 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 MIG welds, the higher TIP TIG weld pool energy generated with any all position TIP TIG welds, should always  enable the best possible weld fusion potential and always the lowest weld porosity formation potential. 
Always remember that apart from attaining the highest manual or automated weld quality potential, TIP TIG will also always enables the lowest possible weld heat input. And now think about what that does for mechanicals, for corrosion, distortion, stresses and cracking concerns.

Please note when comparing TIP TIG with Pulsed MIG, that the  TIP TIG welds  not only provides much greater arc temperatures, the TIP TIG weld are  also protected by an inert gas.  So in contrast to MIG, with TIP TIG there are no CO2 or O2 reactions that always influence MIG weld porosity and MIG weld surface cleaning. Also with the Reverse Polarity (RP) Pulsed MIG weld, most of the MIG weld energy is highly focussed in the arc plasma, which is necessity to melt the MIG wire.

That MIG Reverse Polarity plasma energy concentration at the wire tip area of the plasma, results in high localized weld heat that has great influence on the MIG weld heat affected zones. In contrast  with the electrode negative (EN) polarity  TIP TIG process, the majority of the TIP TIG plasma energy is driven to the base metals and with the weld speeds attained, enables the lowest possible weld heat input which enables extraordinary weld and  part metallurgical benefits as discussed below. 

WHEN ITS EASY TO USE IT ENHANCES THE WELD QUALITY POTENTIAL: The following, relaxed, pipe root TIP TIG welder still uses on the root, the same  walk the cup welder techniques as any TIG welder, however with fillet welds the TIP TIG welder will use weld techniques similar to MIG welds. 

Question.  Some may wonder how TIP TIG enables both the highest available arc weld energy while enabling the lowest weld heat capability?

Answer on weld energy. In contrast to a traditional DCEN TIG weld, the constant fed, smaller diameter TIP TIG weld wires typically enable a 100 to 400% increase in the TIG weld deposition rate capability. The increased weld deposition with the smaller TIP TIG weld wires enables increased TIG weld current to be used. As the TIP TIG weld wire and weld droplet transfer into the weld plasma provide minimal influence on the TIP TIG arc plasma energy and on the weld surface, therefore with the higher TIG weld current used, smaller wires utilized and more of the TIP TIG plasma affecting the fluid weld surface, the TIP TIG welds will provide greater weld energy than any other arc weld, and lets not forget the influence of the TIP TIG weld agitation which also helps slow down the weld solidification and adds to the weld fusion and reduced porosity capability.

For those weld shop managers and supervisors that care about looking for real world methods to reduce their weld shop labor costs, please note the TIP TIG increased weld deposition reduces DCEN TIG weld labor and weld gas costs typically in the range of 100 – 400%. Also in contrast to TIG, the weld wire costs are reduced typically by 15 – 25%.

Answer on Low Weld Heat. The increased TIP TIG weld deposition that’s possible on most parts > 1/16, (>1.6 mm), enables “higher TIG weld speed capability”. The faster TIP TIG weld speeds combined with DCEN polarity, (EN = work becomes large heat sink) enables extraordinary TIP TIG low weld and part heat that can provide extensive reductions in weld distortion and weld stresses. The low weld heat enables extraordinary weld & part metallurgical results that have never before been attained anywhere in the arc weld industry.

So today in most weld shops, we have traditional DCEN TIG with often slow weld travel rates of 1 to 5 inch/min that can create high weld & part heat, and we also have reverse polarity MIG and Gas Shielded Flux Cored that also provide high part heat, so these three arc weld processes typically end up with large weld heat affected zones.

In my next blog and in my TIP TIG self teaching / training program there is much data on TIP TIG welding alloys. And you will see why in 2019,  that the  TIP TIG  process is the only global Arc weld process with it’s low weld heat ability that can weld most  titanium parts > 3mm, without the use of a Gas Trailing Shield, and those titanium welds will meet any  Aerospace, Defence. Oil or Nuclear weld quality requirements.

As most alloys and high strength steels are 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, ten year old process such as TIP TIG that always enables both the highest weld quality potential with the lowest possible weld joules. 

I did the following untouched  steel fillet weld.

Is your weld shop using more than one weld process
for root and fill passes?
 

Most global weld shops would consider choosing two arc weld processes for their open root and fill passes on pipe or plate welds. Processes such as TIG & Pulsed MIG or  Stick & FCAW and  TIG & FCAW or STT / RMD MIG & flux cored. Please remember that  TIP TIG is optimum for all position roots and for all fill passes.

Irrespective of the weld automation or the manual welder’s skills utilized, with MIG, SMAW and flux cored, as  NDT would reveal, there will often be process influenced weld fusion – weld slag – weld porosity issues, and with the inconsistent manual welder skills, the weld shops will typically anticipate some weld rework.

Of course the weld shop may may simply choose to  do the pipe root and fill passes completely with the super slow, time consuming DCEN TIG process as any country’s  Navy will attest, the weld defects mostly a result of the welders skills will still be an issue. In contrast, using my TIP TIG training program and the two simple TIP TIG weld settings that I recommend for any pipe or plate  welds, the weld shop should  anticipate using X-Ray evaluation, zero weld rework. The easy to use 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.

TIP TIG Small Tubes Heat Exchange.

Imagine the weld benefits on these small diameter heat exchange tubes when you don't have to feed a wire and don't need a foot control. These welds easily made were as good as the welds made with automated equipment and TIP TIG put in less weld heat.

From pipe to heat exchange tube welds, with minimal manual skills, the manual TIP TIG welds as below, should look like automated welds. 

TIP TIG larger tube Heat Exchange welds.

Note with these untouched all position, manual TIP TIG welds. Note the weld continuity, the smallest possible weld HAZ, the optimum weld tie-ins, and a weld appearance that look like automated welds.

Weld Automation and more on TIG Arc Length Sensitivity.


Automated TIP TIG Weld Benefits.
In contrast to pulsed MIG which is often used with automated welds, the TIP TIG automated welds will produce welds with much smaller weld  Heat Affected Zones. The TIP TIG welds will enable the smallest possible weld distortion and stresses. The TIP TIG welds will have no spatter, no weld fusion, no porosity or fume concerns. TIP TIG welds with low oxidation potential will also be easier to clean. And for the first time in 70 years this sentence can be written about an arc weld process. With attention to weld placement, TIP TIG welds should not require weld rework.

So with regular DCEN TIG, its the the common low weld deposition rates with slow weld speeds and the  restricted current content that’s based on those weld deposition rates, and also the TIG tungsten erosion that’s  influenced by the large weld wire placed in close proximity to the tungsten tip along with the TIG arc length sensitivity, are the reasons that the traditional DCEN TIG process has often been a poor choice for automated weld applications which require filler metal, applications that  don’t have automated arc length control equipment.

Why Arc Length Control equipment is not required with automated  TIP TIG welds: In contrast to TIG, the TIP TIG process provides higher deposition rates usually 100 to 400%  more weld that results in  higher weld speeds that are better suited to weld automation investment. The higher TIP TIG deposition rates enable increased weld current, and the  unique TIP TIG weld droplet transfer that enables more of the arc plasma to impact the surface weld energy are factors that assist in the electron flow which reduce arc length sensitivity concerns. With TIP TIG you  are getting  a multi-process  from the use of a manual process, or very effective automated process.

 

TIP TIG easily adapted to robots.

Click here for my robot and manual  MIG and TIP TIG weld process controls – best weld practice, self teaching / training programs

When I was the USA weld manager at ABB Robotics, one of the world’s largest Robot Mfg, companies, the engineers and I would not be comfortable with robot applications that required the traditional  DCEN TIG process. The prime reasons for the discomfit was  due to the TIG arc length sensitivity issues, the tungsten contamination, wear influence on the welds,  the arc stability influences by electron flow issues, and also the typical slow weld speeds. A few years after I left ABB, I returned to their Colorado location introduced the ABB USA welding group to the TIP TIG process.

TIP TIG brings a unique process to welding robots.

Around 2010, a few years after I left the ABB Robot company, I went back to the ABB head office in Fort Collins CO,  to provide their engineers and managers with a seminar on TIP TIG.  The seminar was about the new unique robot weld application opportunities enabled with the TIP TIG process. During the workshop, I went step by step over why the TIP TIG process was unique and the weld and application feature benefits. I also pointed out how TIP TIG eliminated the normal TIG robot weld concerns. I pointed out to the ABB group  that this new process was ideally suited to numerous, new  robot applications, and would especially be beneficial with any code quality welds and on all high strength steels, low alloy steels and alloy applications. Think about those new robot Defense, Aerospace, Power and Oil – Gas applications.

The ABB engineers were impressed, however  like many young weld engineers and managers from Ohio State and LeTourneau they also lacked arc weld process controls  and weld application expertise, and so they lacked the confidence that was necessary for them to buy into marrying TIP TIG to their robots. However all was not lost, as eight years later,  around  2017,  some brighter ABB engineer or sales manager woke up to weld reality,  and finally figured that TIP TIG would open up many more robot weld application opportunities, and  therefore should be their  arc weld process of choice when in contrast to DCEN TIG and Pulsed MIG, superior weld quality, superior weld & part mechanicals and the lowest possible part distortion  was required.

Sometimes managers will lament. “Another big job coming up and we can’t find the necessary SKILLED TIG WELDERS”

This company used to use mostly pulsed MIG and flux cored on it’s large ship Duplex vessels,typical  thickness range, 1/8 to 5/8. As the vessels were used to transport beverages, food industry specs were in place and weld  spatter and cleanliness was always an issue. Weld distortion and the weld fumes from stainless and duplex were also issues. This large company now does most of its welds with TIP TIG and never has weld quality, distortion, spatter or weld fume issues.


With no wire to feed to the welds and no foot control required for controlling the weld amps, the TIP TIG job on the left is simplified, and let’s face it, the welder is much safer in that they can can  hold on to the part while TIP TIG welding. The company wanted no spatter, no distortion, no fume concerns and no weld rework, that’s what they got.

TIP TIG dramatically reduces all position welder skills. A TIG welder needs a day to learn this process and about 10 hours with my TIP TIG self teaching / training course. Someone who has never TIG welded can in a week pass most all position code welder qualification tests. With TIP TIG another skill not required is the correct wire placement.  The TIP TIG weld wire is always delivered into the arc plasma periphery sweet spot. Also as with MIG, the continuous fed TIP TIG weld wire drives the welders speed.  With TIP TIG a foot control is not necessary, weld start and stop data is always optimum and delivered from the TIG power source with the torch trigger commands. 

In contrast to any all position DCEN 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. Below, first time, TIP TIG rotated pipe weld reveals to the weld shop, pipe weld quality never before attained. 


TIP TIG defects not allowed.

Can we produce welds that will meet the most stringent ASME NDT requirements and not require weld rework?  For seven decades this not something that weld shops  would want to hear when using traditional, manual arc weld processes.  However with TIP TIG, it could be proven in minutes. 

Think about the billions of dollars annually spent around the world on the costs associated with weld testing, weld rework and weld rejects.

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 first time expect to attain the best mechanical and corrosion properties with all steels, alloy steels and alloy applications. 

By the way, with my Self Teach or 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.


Nice to be able to put two hands on the TIP TIG torch, and
not be bothered by a foot control, weld spatter or fumes.

While the low deposition,  regular DCEN TIG was often poorly suited for large size and thick applications, this has changed with TIP TIG.  Weld applications any thickness > 1/16, applications big or small, the all position TIP TIG welds can typically be done with a couple of weld settings and with no weld cleaning, no distortion, no weld rework be cost effective.  It’s also as above nice, to enable lower welding skills and  be able guide the light torch with two hands, and not worry about weld fumes

Remember benefits from reduced weld preheat – interpass or postheat. By the way as a reminder, remember when you dramatically  reduce weld heat input, it’s also likely  you can eliminate inter pass weld temp and reduce or eliminate preheat and post heat. Of course you could ignore these game changing weld benefits, as as most do in 2019, continue to arc weld the way it’s been done since TIG was first introduced in the 1940s.

TIP TIG is much more than a “ONE OFF weld process solution for a companies weld problem.  

Many of the few global TIP TIG sellers while exited by their TIP TIG 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 if weld repairs were required would result in costly rejects or 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 daily in the weld shop for the code quality welds continue to be traditional TIG, pulsed MIG or flux cored process.  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. By the way consider the new business opportunities that come with TIP TIG as any alloy welded with this process is as easy to weld as carbon steels.

2019. So now TIP TIG has been available for more than a decade:

[] Consider TIP TIG  when quality welds are required that will not require weld rework.

[] Consider TIP TIG when the lowes weld distortion or stresses are a benefit.

[] Consider TIP TIG if you are now using two weld processes for the part welded.

[] Consider TIG TIG FOR when all position welds are required.

[] Consider TIP TIG if you want the cleanest welds with lowest weld fumes.

DCEN TIG: Welds and CostsTIG weld costs are rare discussion with a process that often produces welds at the speed of a turtle. It’s more likely the weld shop will be concerned about not having enough skilled TIG welders. So let’s take a look at TIP TIG weld costs. So below we have two weld shops bidding on a new five years code quality weld contract, they need compete with each other. 

Shop One:  USED  TRADITIONAL TIG: 

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: BID ON THE WELDS USING TIP TIG:

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 obtained 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.

 

 

Rarely discussed in weld shops. DCEN TIG Deposition rates.

Let’s say that manual TIG welder is welding pipe and using a common 3/32 steel or stainless TIG wire for the pipe vertical up fill passes. The welder typically would feed around 8 to 10 inch of the 3/32 wire length each minute.  8 inch/min of 3/32  wire is approx.  1 lb/hr. However with a manual DCEN TIG deposition of 1 lb/hr and an average arc on time of 20 min/hr, those TIG  welders are typically depositing  on average approx. 0.03 – 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 2.5lb/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 times dramatically.  

While the manual DCEN TIG pipe welder is depositing 0.4 lb/hr, in contrast, with the manual TIP TIG pipe welds, and the increased  arc on time of  say 40  min/hr, the TIP TIG welders would  typically deposit  on average  about 1.6  lb/hr, this simply means the TIP TIG welder is depositing 300% more TIG weld each hour than the regular TIG welder.

You don’t have to be a rocket scientist, to figure out that this simple weld cost comparison between a manual TIP TIG and manual TIG welder would have has major weld cost and labor requirement ramifications for any company that employs welders. 

Confusion between Automated 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. 

There are many different trade names automated Cold Wire (CW) TIG processes available, from my perspective they are a waste of money as they usually provide limited weld application value.

The reason for the ditain with the TIG Cold Wire processes  is that the weld deposition rates attained  is typically no more than what  a manual TIG welder can attain on the same application. The CW processes are also arc length sensitive and arc outages during the weld are prevalent.


Typical Hot Wire TIG High Amp Clad Application.

 

In contrast to HW TIG, with TIP TIG you have a wider amp weld application range. TIP TIG also eliminates arc length sensitivity concerns and where as HW is only suited to automated welds, with TIP TIG the weld shop has both a manual and automated process.

 

That Hot Wire (HW) weld, is a DCEN TIG weld, plus a MIG wire feeder that provides a continuous fed wire through a TIG torch. The  wire is preheated  by a separate,  small HW power source that usually provides 80 to 120 amp. The HW wire preheat adds additional energy into the weld pool which slightly reduces arc length sensitivity concerns. Note the clad application on the left where due to wire feed and melt issues its beneficial to feed wire into the rear of the weld pool. A poorly understood feature of many automated, “all position” Hot Wire OD or ID pipe welds, is the limitations that are occuring.  

HW always works better with high amps as the plasma is usually larger and more intense and therefore less arc length sensitive. With low to medium HW weld amp applications there is increased  arc length sensitivity concerns with the  faster weld freeze applications and they may require costly Automated Arc Length Equipment. Also  on some applications the HW torch may require to attain it’s wire melt continuity, by feeding the weld wire into the rear of the arc, see video below.

In contrast to HW, with TIP TIG you have a process suited to both manual and automated, low to high current applications whereas Cold Wire is a waste of money  and Hot wire is not suited to most manual welds.  Take a moment to view the HW weld below.

Why TIP TIG could be ideal for Clad Welds. Many clad weld applications, will thanks to the weld dilution require two or three weld layers to get the desired chemistry which likely could be attained with one weld layer using TIP TIG.

How does TIP TIG enable optimum clad welds on many parts? TIP TIG enables very low weld heat and also without Arc Length Controls, enables fast weld speeds with rapid weld weave oscillation without concern for arc outages, The EN polarity, the fast weld speeds and rapid rate weld weaves can enable the lowest possible single pass weld dilution. 


In contrast to HOT WIRE video above,
again take a close look at TIP TIG.

EVALUATING HOT OR COLD WIRE WELDS, PLEASE EXAMINE THE WELD WIRE SIZE USED,  THE WIRE FEED RATE AND THEN WORK OUT THE WELD DEPOSITION:

With many thin wall applications < 1/4,  < 6mm, when using HW or Cold Wire on all position pipe welds, take a look at the wire feed rates being  achieved. Remember a manual TIG welder puts in a little more or less than one pound per/hr. That HW or Cold wire automated weld using an 0.023 steel wire maybe  running in at approx. 140 inch/min. That  sounds much more cost effective than the manual TIG welder feeding their 3/32 wire at 8 inch/min.  However that 140 inch of 0.023 wire also provides a pound/hr.  Or the HW weld maybe using an  0.030 steel wire  running at approx. 80  inch/min again a pound/hr. 

To help you work out wire size, feed rate to deposition,  70 inch/min of 0.035 (1mm) wire is approx. pound/hr. While 70 inches of 0.045 (1.2mm) wire, is approx. 2 pound an hour.

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

Today after more than 50 years in this business. and all I have to do is walk my dog,  think and write about welding, I figured that a weld process comparison blog such as this, and access to my unique Weld Process Control self teaching / training programs on TIP TIG – Advanced AC/DC  TIG – MIG / Flux Cored and Robot MIG welds, would be helpful for those few that are beginning to believe in the importance of weld process ownership and  weld process controls – best weld practices.

Em in 2018.

Feb 4. 19. Ready for change. Contact  Em at 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.  For Em’s TIP TIG, or MIG and Flux cored  Weld Process Controls & Best Weld Practice, Self Teaching / Training Programs.