Compare TIP TIG with TIG, MIG & Hot Wire TIG.

DC TIP TIG provides superior weld quality and mechanical properties, and also 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 typically in the range of 200 - 400%.

2019. Emily Craig: After studying the  TIP TIG process versus traditional DCEN TIG process now for more a decade, you will find the TIP TIG versus  DC TIG,  Pulsed MIG and Hot Wire TIG comparison data available at this site, is from a weld process and application evaluation, unique practical, cost effective and comprehensive. 

Note: I have spent hundreds of hours writing and rewriting  this TIP TIG section, and thousands of hours writing the MIG, flux cored and TIG arc weld data in my  weldreality web site, a site that for more than two decades has focused on the weld quality and cost consequences  of  lack of global weld process controls and best weld practice expertise.  The 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 arc weld issues. My  weld data  is always factual and provides numerous, cost effective weld  solutions,  I would therefore appreciate that if you wish to use any of my copyright protected data, that you please request  my permission at, ecraig@weldreality.com.  

 

The evolution of  the 70 year old DC TIG  process is 


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 DC TIG and Pulsed MIG weld differences and applications, so  let me provide you in the first few  paragraphs, ten years after its been introduced, some prime Weld Quality – Weld Cost reasons that any company that provides code quality steels and alloy steel welds, simply cannot afford to ignore.

AS OPTIMIZING WELD QUALITY AND REDUCING WELD COSTS SHOULD  BE OF INTEREST TO MANY IN THE GLOBAL WELD INDUSTRY, I would like to start out by simplifying the extraordinary weld cost savings and weld quality improvement potential with the  TIP TIG process.

A SUMMARY OF DC TIP TIG VERSUS TRADITIONAL DC TIG PRIME WELD BENEFITS WOULD BE;

[a] TIP TIG ENABLES  FAR SUPERIOR WELD QUALITY,

[b] TIP TIG ENABLES THE LOWEST WELD HEAT, (LOWEST DISTORTION & CRACKING POTENTIAL) & ALWAYS FAR SUPERIOR METALLURGICAL PROPERTIES,

[c] TIP TIG REQUIRES MUCH LESS WELDER SKILLS, REQUIRES NO MORE THAN 3 WELD SETTINGS FOR ALL WELDS,

[d] TIP TIG IS READILY SUITED TO MOST MANUAL AND AUTOMATED WELD APPLICATIONS,

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

SO LETS LOOK AT A TYPICAL AEROSPACE WELD DEPARTMENT &  ITS TRADITIONAL PRIME TIG WELD COSTS : Reference the “annual”  TIG weld labor and consumable costs, in a weld shop that employs a number of DC TIG welders, with a change from the  DC TIG  to the TIP TIG process, the weld shop should anticipate at least a  65 – 75% annual weld 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 and weld quality  impact from TIP TIG on any company that provides Code Quality steels and alloy welds. The following provides how I attained  a  70% weld cost reduction.

Fighter PlaneLets 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 their 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 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,  plus the  two weld supervisors at $80,000 /yr with their combined annual salary of $160,000.yr.

The above annual TIG weld shop wages total is $1,065,000. The TIG equipment equipment investment for 10 welding  units, approx. $78,000.

TIP TIG WELD 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.
As you  you can see with the added weld consumable savings , that an approx. 70% annual TIG cost savings would be anticipated.  The TIP TIG total weld equipment costs for those  3 units, depending on what TIG power sources are in place, would be in the approx. range of  $55,000 to  $80,000.

The above annual TIP TIG weld shop wages total is $292.000. The annual TIG weld shop wages $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 provided in the Pulsed MIG section, the Pulsed MIG will always produce inferior weld and part quality with special concerns for weld fusion and porosity issues..

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 such as found  in the Aerospace, Defense  and Medical industries, the more common the isolation of the front office managers and engineering  decision makers are from the manual weld process decisions that are being made on the weld shop floor.” And as you will see in this “play around with weld controls, and why change the way we have always done it industry”  lack of management & engineering weld process ownership often leaves the weld shops without impetus for progressive weld change and typically the weld shops are stuck  in the 20th. Century with the weld processes, weld  practices, procedures and specifications utilized.

As the weld cost savings and weld quality improvements enabled by TIP TIG and the implementation of 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, the question becomes;

WHO AT THE CORPORATE OR PLANT MANAGEMENT LEVEL WILL STEP INTO THE 21 st CENTURY & TAKE  WELD PROCESS OWNERSHIP NECESSARY TO DRIVE AND IMPLEMENT THEIR COMPANIES  WELD QUALITY IMPROVEMENTS AND WELD COST REDUCTIONS? 

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 enables superior weld quality with less 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.

HOW LONG DOES IT TAKE TO TRAIN SOMEONE TO USE TIP TIG?  If the welder is a TIG welder it typically takes one to two days.  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.

The following corporations are typical of those that could create millions of dollars annually in weld cost savings with dramatic weld quality improvements. GE, Westinghouse, NASA,  SpaceX, Boeing, BP, Shell, Airbus,  Exon, Lockheed, Saudi Aramco, Northrup,  Raytheon, Phillips, Cameron, BAE, Total, Rolls Royce, United Technologies, General Dynamics. At these and similar corporations, most of the steel and alloy steels, code quality welds are in 2019 being made with the DC TIG  and the inferior Pulsed MIG process. Also at most of the high tech  corporations,  you will find minimum weld  focus on weld process controls and best weld practice expertise, and this 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 using Weld Procedures &  Specifications that were likely generated in the 20th century.


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


LOOK AT THE WELD QUALITY AND THE WELD TIME:

Examine the TIP TIG 16 gauge stainless fillet weld above. In contrast to your TIG welders, note the weld speed and time required for the weld length of 18 inch, and note the weld quality continuity and uniformity and the silver weld color that indicates lack of oxidation, (lowest weld porosity potential). No spatter, no weld fume concerns. And of course the smallest possible weld HAZ which means the lowest weld distortion, the lowest weld stresses, the lowest possibility of weld cracking and the best possible mechanical or corrosion properties on thin parts that would normally be subject to high TIG weld heat.  \

REMEMBER IT DOES NOT MATTER IF ITS PROVIDING WELD SHOP PERSONNEL WITH SOMETHING FEW HAVE EVER BEEN PROVIDED, WELD PROCESS CONTROLS – BEST WELD PRACTICE TRAINING, OR INTRODUCING THE WELDERS TO A NEW COST EFFECTIVE ARC WELD PROCESS SUCH AS  TIP TIG, THESE ARE CHANGES THAT SHOULD BE DRIVEN BY THE RESPONSIBLE  MANAGERS AND ENGINEERS.

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

Ref: My above TIP TIG Weld Process Controls and Weld Practice Programs:  No matter what the skill level of the welder is or the years that they have welded, front office weld decision makers and weld shop personnel should learn the unique TIP TIG weld practices, techniques, and the few required optimum weld settings that I generated that are suited to every possible steel and alloy steels weld application. My easy to learn TIP TIG,  (MIG and  Flux Cored) Self Teaching / Training  programs require approx. 15 hours, so if you want to train the employees yourself and don’t want them “playing around” with the TIP TIG controls as most  have done for decades with the two simple controls used with their MIG and flux cored welds, this is a good path to take for the three weld processes.

MANAGERS – ENGINEERS – SUPERVISORS: If your organization is interested in achieving the TIP TIG process change, I could help in a number of ways. First invest in the few dollars it takes to purchase  one of the above process programs and evaluate the programs  importance and relevance to your organization. Then with these simplified TIP TIG – Manual – Robot MIG and Flux Cored programs, evaluate if this is something you want to do yourself or get assistance from me. As for TIP TIG,  I could  present a TIP TIG Weld Application workshop  to your managers, engineers, supervisors and  I could provide my hands on  unique, simplified TIP TIG training program  to your welders, supervisors and  trainers. Or on a short term contract basis,  I could  be the catalyst, trainer and mentor required to enable  the process changes and get the new weld procedures implemented. 

Not  interested in TIP TIG, but would enjoy the best and most comprehensive  information on Pulsed MIG, Flux Cored and MIG weld gas mixes 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.

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, the sometimes the use of a foot amp control,  have for seven decades been important  prerequisites of  the manual TIG welder’s skills, that in reality for more than a decade have no longer been required with DC TIP TIG.

TRADITIONAL DC TIG WITH POOR ARC PLASMA ENERGY DISTRIBUTION & 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.

FANCY NEW GLOVES, NEW TIG TORCH, WORK JACKET & HELMET, USING AN OUTDATED 20th CENTURY WELD PROCESS.

2018: WHEN A WELD SHOP UTILIZES THE ABOVE 70 YEAR OLD,  DC GTAW (TIG) PROCESS INSTEAD OF DC 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.


I STARTED MIG, TIG & FLUX CORED WELDING AT MASSEY FERGUSON, MANCHESTER, UK. IN THE NINETEEN SIXTIES.  IF I COULD TAKE YOU BACK  TO THE SIXTIES, AND WE WERE ABLE TO USE THE TIG AND MIG EQUIPMENT EQUIPMENT AVAILABLE, IN A FEW MINUTES  I WOULD SHOW YOU  HOW TO  PRODUCE OPTIMUM MIG AND TIG WELD QUALITY AND PRODUCTIVITY ON ANY STEELS & ALLOY APPLICATIONS, WELD QUALITY AND PRODUCTIVITY THAT CANNOT BE SURPASSED WITH THE ELECTRONIC WELD EQUIPMENT AVAILABLE IN 2019.

Thanks to the general  lack of global weld process controls expertise, for decades, too many in the  weld  industry have relied  on weld sales advice. From my perspective, (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 AT MY WELD PROCESS CONTROL – BEST WELD PRACTICE SELF TEACHING / TRAINING RESOURCES.

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.

Its a new day: 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.

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.

Too help understand TIP TIG  take special note of what is going on in  the TIP TIG arc plasma periphery, at the wire tip and the weld surface.


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 MIG. I 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.

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 wants 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 the sad reality is that it’s also likely 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 not be aware of the TIP TIG weld application potential. Also most aerospace  companies  will be using Arc Weld Specifications and  Weld Procedures and weld guidelines that were likely first established three decades ago. 


If you worked in a weld shop, you may have heard this.