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TIP TIG

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  • TIP TIG is the only semi-automatic weld process capable of consistently producing optimum, all position code quality welds on carbon steels or any alloy applications without concern for weld rework and without concern for the effects of weld heat on the alloys welded.
  • TIP TIG is the only process capable of delivering the highest possible weld energy (optimum fusion-minimum porosity) with the unusual benefit of also providing the lowest possible weld heat. These two benefits are necessary to consistently attain optimum code quality welds and the solution to resolve most alloy weld issues that occur with regular TIG and pulsed MIG.
  • With TIP TIG, the constant fed weld wire is superimposed by a secondary, high speed oscillation which is generated by the patent pending four roll, mechanized drive plate. The mechanical action of the drive plate generates a vibration that passes through the weld wire into the weld. The vibration agitates the weld pool. A secondary influence on the TIP TIG weld is the hot wire current which pre-heats the weld wire, improving the wire receptivity into the TIG weld. The agitation of the TIP TIG weld and the added weld energy creates unique TIG weld dynamics which slow down the weld solidification. Enabling longer TIG weld fluidity allows more TIP TIG weld wire to be fed into the weld pool. The increase in TIP TIG weld wire enables more weld current which further enlarges the TIG arc plasma and further increases the weld energy. This also reduces arc length sensitivity and improves the arc stability.

The TIP TIG welding process

The TIP TIG welding process is a very unique hot wire TIG welding process for automated welding, bore cladding, orbital welding and aluminum welding that uses our patented wire feed technology. The benefits of our system will provide the highest quality, highest deposition rates with the lowest possible heat input values consistently delivering the greatest metallurgical results on all alloys and it has also proven to provide the lowest possible hexavalent chrome weld fume emissions which have been measured as undetectable.

Unlike nearly all other hot wire TIG welding processes, it can be operated both manually in all positions, as well as with our patented automation systems. A widely recognized benefit we deliver is the reduction in labor cost associated with costly rework and training. It's just simple to use, teach and to learn!

The TIP TIG welding machines are wire fed GTAW systems that create a vibratory force on the welding wire in addition to applying hot wire current to the filler metal prior to entering the weld puddle. The vibratory effect is created by a sinusoidal mechanical agitation created by the custom wire feeder system and the hot wire current is created by a secondary power source within the TIP TIG welding machine. Take some time to explore the benefits of TIP TIG welding on various alloys such as Carbon Steel, Stainless Steel, Duplex and Super Duplex Stainless Steels, Inconel, Stellite, Titanium, Aluminum, Hastelloy, Copper Nickel, Nickel Chrome Alloys and many others.

How it works

The unique TIP TIG weld dynamic slows down the weld solidification process and enlarges the fluid weld area. The TIP TIG weld changes, improve the TIG weld receptivity for higher weld deposition rates. TIP TIG typically enables a 100% to 400% increase in TIG wire feed rates which also allows higher weld current to be used. The resulting faster TIP TIG weld speeds and higher than normal TIG weld energy enables numerous TIG weld quality and productivity benefits.

TIP TIG Benefits

In contrast to the regular TIG process, on the majority of TIP TIG applications you can typically attain a 200 to 400% hourly increase in your TIG weld production and up to 60% in reduced TIG weld costs, (check out the data in the TIP TIG versus TIG in our blog). While the manual, regular TIG weld speed range is typically 2 to 8 IPM, manual TIP TIG welds are usually made in a weld travel range of 8 to 50 IPM. With the the TIP TIG weld cycle time reductions you can anticipate at least a 30 - 60% reduction in your TIG gas costs. Also using the less expensive MIG wire reels will lower your TIG wire costs. Those of you welding with conventional vee grooves of 65 to 80 degrees check out further savings below. By the way, if in the past you have been are concerned about weld rework and weld cleaning labor and consumable costs (grinding wheels - brushes) that should no longer be a concern.
There is a global shortage of skilled TIG welders. In contrast to regular TIG, the TIP TIG welder does not have to feed a wire into the weld, also a foot control is not necessary. With TIP TIG the welders can keep their focus on what is happening in the weld pool and use one or two hands to guide the torch. TIP TIG, manual TIG welders with “low to moderate weld skills” will have the potential to produce extraordinary all position weld quality and those welders with high TIG weld skills will have the potential to attain a weld quality beyond that achieved with most costly TIG weld automation.
Go to any stainless or duplex work shop and listen to the discussions on the numerous weld and metallurgical issues that can occur with these complex alloys. If you were utilizing TIP TIG at your facility, you would sit back and smile, as the majority of problems under discussion can not happen with a weld process that consistently delivers the highest possible weld quality with the lowest possible weld heat. In contrast, if however you were using regular TIG, you would have a process that delivers high weld energy with high weld heat, while pulsed MIG and Flux Cored would both deliver moderate weld energy and high weld heat. The higher TIP TIG weld energy and agitated TIG weld pool will produce welds that have least potential for lack of fusion - weld pores - inclusions. The lowest heat from TIP TIG results in the lowest possible weld oxidation, the lowest weld distortion, the least weld stresses and the welds will require the least weld cleaning. When the world's largest nuclear plant (Hanford WA) wanted to weld 40 inch stainless pipe to the highest weld standards, they turned to TIP TIG. TIP TIG. no need to feed a wire, no foot control, less skills required, the least chrome - manganese weld fumes and lowest weld fatigue. TIP TIG, better weld quality and lower heat than any process, no weld cleaning, best mechanical - corrosion properties. TIP TIG 200 - 300% more weld each hour than TIG and as cost effective as MIG -flux cored. The lowest possible weld heat from TIP TIG can if required reduce weld - clad dilution which with stainless welds typically means more chrome and nickel for the welds adding to the weld's corrosion resistance. More chrome for the weld also means more ferrite which again improves weld crack resistance. With those pulsed MIG, Flux Cored, Metal Cored clad welds that require 2 tor more weld layers, with TIP TIG you will like get the clad results often with a single layer. When your welds are the cleanest possible, with TIP TIG stainless welds you should eliminate the need for passivation and eliminate the labor / consumable costs associated with weld grinding and cleaning. With duplex and austenitic welds ferrite control is easy. With any alloys , attaining optimum impact or the best possible mechanical or corrosion properties should always be a simple task. Every steel and alloy will benefit from a weld that will consistently produce the highest weld quality with the lowest weld heat.
The TIP TIG agitated, higher energy, more fluid, slower solidifying weld pool should always provide the best possible side wall weld fusion on any application. This feature typically enables a dramatic decrease in both Vee and J-Groove pipe - plate edge prep dimensions. For example, if your application calls for a traditional, included pipe Vee prep angle of 60 - 80 degrees, if you were using TIP TIG, the included vee edge preps depending on wall thickness could be reduced in the angle bevel range of 40 to 55 degrees. This capability with TIP TIG can enable an additional 25% - 35% reduction in weld labor and consumeable requirements.
Watching a welder using SMAW, Pulsed MIG or Flux Cored on a stainless or other chrome nickel applications (hexavalent issues) and you can readily see and measure the weld fumes generated. Watch a welder using TIP TIG on this sites videos and on clean applications, if the correct data is used it's going to be difficult to see or measure the weld fumes. The regular TIG manual process creates the highest welder fatigue. TIP TIG eliminates feeding the TIG weld wire or operating a foot control. As TIP TIG welds are made 100 to 300% faster than TIG, fatique and ergonomic concerns should be eliminated with the TIP TIG process.
The ability to utilize a single process for any weld can solve many weld shop issues. Weld managers will be pleased to know with pipe, plate and vessel welds, that from the root to the cap they can use TIP TIG. If the welders are qualified for TIG the are qualified for TIP TIG. If you have qualified ASME procedures for regular TIG you can use those procedures for TIP TIG. Using three or four common TIP TIG weld settings, the welders can weld or clad any alloy, any thickness and make those welds in any position. With TIP TIG we can produce 6 to 8 mm, single pass. fillet welds or weld on thin gage (> 16 gage) metals with ease. With TIP TIG we can attache the manual torch to a mechanized carriage or a rotary turntable and this process can be used with robots and most automated welds without costly, complex Arc Voltage Control equipment. It may sound far fetched, but in a 30 minutes demonstration we can show you the four simple weld settings that could be used on every weld in the construction of a nuclear plant or submarine. If you have an interest in this process give us a call, send samples (we weld and video for you) or visit us at our New Jersey facility. In a short weld demonstration, we will show your organization the highest possible, untouched weld quality always with the lowest weld heat.
Due to the higher TIG weld current, (higher weld energy) and the unique, "agitated weld pool”, the TIP TIG welds will always provide superior TIG weld fusion when compared to regular TIG and the automated Hot Wire TIG processes . TIP TIG is the process that provides the lowest possible weld oxidation from the faster weld speeds combined with electrode negative and an inert gas resulting in the cleanest possible welds. These welds will have the lowest weld porosity-inclusion defects. When dealing with welding sluggish alloys such as Duplex - Inconel - Invar - Stainless and high carbon steel applications, the increased energy and agitated weld pool of TIP TIG dramatically reduces concern with the fusion and porosity issues of these materials.

Cost comparison

The following comparison shows the actual savings calculated on a real stainless steel welding application comparing conventional TIG and TIP TIG on a pipe application (2″ Sch 80 Stainless) in the 5G position.

Variable / Result Units Conventional TIG TIP TIG
Welding process GTAW GTAW
Wire type ER308L ER308L
Wire size 0.0930 0.035
Wire feed speed IPM 3.98 78.00
Melt off rate lb/h 0.48 1.27
Deposition efficiency % 100% 100%
Deposition rate lb/h 0.48 1.27
Duty cycle % 100% 100%
Final deposition rate lb/h 0.48 1.27
Gas type Argon Argon
Flow rate cfh 30 30
Gas/Wire ratio cf/lb 63.05 23.62
Gas price $/ccf 7.98 7.98
Wire price $/lb $ 5.66 $ 5.66
Labor and overhead cost $/h $ 100 $ 100
Wire purchased per year station lb 1 1
Number of welding station 1 1
Welding cost per lb of wel deposited
Wire costs process $ $ 5.66 $ 5.66
Gas costs $ $ 5.03 $ 1.89
Labor costs $ $ 210.16 $ 78.74
Total costs $ $ 220.85 $ 86.29
Estimated potential savings
Per lb of wire deposited Cost saving per lb: $ 134.56