THE TIP TIG WELDING HOME PAGE

TIP TIG USA is the exclusive supplier of TIP TIG equipment
in North & South America and Australia.

At TIP TIG we sell unique, manual and automated weld process and equipment
solutions for alloy weld - clad applications that require optimum quality welds.

TIP TIG.
155 9th Ave,
Runnemede.
NJ. O8078. USA.
Phone. 856 312 8164.

No other weld process can consitently provide the manual weld
or automated weld quality thats attained with the TIP TIG process.

After 60 years of slow TIG weld process evolution, welcome to the patent pending TIP TIG process. In contrast to regular TIG: [] With TIP TIG you dramatically reduce TIG pipe weld skills as the welder does not have too feed a TIG weld wire or use a foot control. [] TIP TIG welders should always achieve superior weld quality than that possible from manual TIG or automated Hot Wire TIG welds. [] Using TIP TIG, you should increase your hourly manual TIG pipe and fabrication weld production in the range of 100 - 300%. [] With TIP TIG, you should always attain better mechanical and corrosion properties than any manual, TIG alloy weld. [] In contrast to any other weld process, with TIP TIG you should always produce the least possible weld heat, the smallest possible HAZ, the lowest possible stresses and distortion. [] Using TIP TIG you should produce the lowest possible weld oxidation and therefore require the least weld grinding or cleaning. [] In contrast to any other weld process, with TIP TIG you should always achieve the least possible weld fumes.

 

 

When you combine the TIP TIG manual weld process with our unique, cost effective, orbital - oscillator and mechanized carriage equipment, your organization will have the potential to provide first time, extraordinary weld - clad quality and productivity. For sales - service - quotes - parts, or if you wish to send weld samples, E-Mail, nick@tiptigusa.com. Phone Nick Corso, 856 312 8164. For optimum TIP TIG weld data or any weld application questions, E-Mail, ed@tiptigusa.com. Phone Ed Craig, 828 337 2695. Please note, It's no good calling your local weld distributor about the TIP TIG process or the TIP TIG automated weld equipment, they don't have it. We are looking for TIP TIG dealers in Canada - Brazil - Australia. EMail Tom at tom@tiptigusa.com.

IN A TIME WHEN MANY COMPANIES STRIVE TO FIND SKILLED TIG WELDERS, IMPROVE TIG WELD
QUALITY AND LOWER TIG WELD COSTS, THERE IS A PROCESS CALLED TIP TIG THAT REQUIRES LESS
WELD SKILLS, PROVIDES SUPERIOR WELD QUALITY AND PROVIDES GREATER PRODUCTIVITY THAN TIG.

At TIP TIG we are well aware that in the sales influenced weld industry, that unnecessary weld equipment bells and whisles and exagerated weld process claims are as commom as bad welds. IF YOU VISIT OUR TIP TIG NEW JERSEY FACILITY, OR IF YOU SEND SAMPLES FOR US TO WELD AND VIDEO, WE WILL MAKE THIS SIMPLE TIP TIG WELD QUALITY PROMISE. It will take TIP TIG USA less than 10 minutes to prove that in contrast to Regular TIG - Hot Wire TIG - TOP TIG - Pulsed MIG or the MIG CMT - RMD - STT modes, that the manual or automated TIP TIG process will always deliver superior all position weld - clad quality.

WELD PROCESS EVOLUTION SHOULD PROVIDE REAL WORLD WELD QUALITY - PRODUCTIVITY BENEFITS. TIP TIG. WELD OR CLAD QUALITY: It does not matter what the weld application is, with the TIP TIG process you will always achieve superior manual and automated weld - clad quality than that attained with the regular manual TIG, the automated Hot - Wire TIG process - Plasma weld or with any sophisticated pulsed MIG weld transfer mode. TIP TIG. WELD PRODUCTIVITY: You can manually TIG weld most applications at average weld speeds of 2 to 6 inch/min, or on most welds you could use TIP TIG and increase your hourly, manual and automated TIG weld production by 100% to 400%. TIP TIG. WELD SKILLS AND PROCESS SIMPLICITY: A good portion of TIG weld skills is manually feeding the TIG wire into the weld and operating a foot control. Neither action is required with TIP TIG. TIP TIG. LESS PROCEDURES: While the use of different processes for pipe root - fill pass welds adds complexity to the weld skills and procedures required, with the TIP TIG process you can weld the root and fill passes in any weld position, on any alloy, any thickness typically using 2 simple weld procedures. TIP TIG. WELD METALLURGY: In contrast to regular TIG, FCAW or any MIG modes, TIP TIG will consistently enable the highest possible weld quality with if required the "lowest possible weld joules"or the widest possible weld joules range. No matter what weld properties you want to attain, you should produce the best possible mechanical / corrosion results with TIP TIG. TIP TIG. WELD ENVIROMENT: Your regular TIG or SMAW welders may work on applications in which they are subject to excess pre-heat or weld heat, radiation or dangerous weld fumes. Please note. If the welders used the TIP TIG process they will achieve the same work in approx. 30% of the time and they will be using a weld process that should always produce the least amount of weld heat with the lowest weld fumes. TIP TIG. CONSUMABLE COST REDUCTIONS. With the faster weld speeds attained with TIP TIG, you can expect a typical 50 to 70% reduction in the weld shielding gas per application. Also for those pipe and vessel applications that require a purge gas, if you can produce those welds in a third of the time you will only need a third of the purge gas. TIP TIG all position weld process benefits; [] With TIP TIG you will achieve welds with the best possible charpy properties. [] With TIP TIG you will achieve welds with the smallest possible weld HAZ. [] With TIP TIG you will achieve welds with the highest possible ductility, strength or hardness. [] With TIP TIG you will achieve welds with the greatest control of ferrite or austenite. [] With TIP TIG you will achieve alloy welds with the least sensitivity to cracks. [] With TIP TIG you will achieve welds with the least possible distortion. [] With TIP TIG you will achieve multi-pass welds with the lowest oxidation, (lowest cleaning). [] With TIP TIG you will achieve welds with the best possible weld fusion. [] With TIP TIG you will achieve welds with the lowest porosity and inclusion content. [] With TIP TIG you will achieve welds with lowest possible weld fumes. [] With TIP TIG you will dramatically lower your TIG consumeable costs. Note: If you are interested in weld cladding, in contrast to any other clad weld process, TIP TIG will provide the highest manual or automated clad weld quality with the lowest possible weld dilution and least possible weld distortion.

WHEN YOU CAN MAKE 5G ALLOY PIPE WELDS LOOK SIMPLE, YOU CAN
APPRECIATE THE TIP TIG BENEFITS ON ANY WELD APPLICATION.

[] TIP TIG will always provide superior pipe quality than TIG and typically increases the hourly TIG pipe weld production in the 100 - 300% range. [] With TIP TIG, pipe welder skills are dramatically reduced. TIP TIG allows the welder to use one or two hands on the torch and no foot control is req. [] With TIP multi pass pipe welds there is no weld spatter, no slag, no grinding, no cleaning required and welders appreciate the lowest possible weld fumes. [] TIP TIG enables a dramatic reduction in pipe prep dimensions typically providing a 20 - 40% reduction in labor and consumable costs. [] Of all available manual and automated welds processes, TIP TIG will produce the lowest weld shrinkage with the lowest weld distortion. In contrast to any other pipe weld process, any TIP TIG alloy pipe weld will produce the smallest heat affected zone. [] The agitated TIP TIG welds promote improved weld fluidity which removes weld fusion concerns with sluggish alloys. [] With any steel or alloy pipe, the improved TIP TIG weld dynamics will in contrast to any weld process enable superior side wall fusion and the TIP TIG welds will have the lowest possible weld pore and inclusion content. TIP TIG, SUPERIOR WELD QUALITY THAN ANY OTHER PROCESS. TIP TIG ONE PROCESS FOR ANY ALLOY, ANY WELD POSITION, ANY THICKNESS.

 

If you want to see how TIP TIG typically reduces your carbon steel or alloy steels
TIG pipe or alloy fabrication weld costs by 100 to 350%,
visit the TIP TIG pipe & manual sections.



If you weld stainless fabrications and want to attain the highest weld quality with the
lowest weld distortion and the least weld cleaning, you should be looking at TIP TIG.

If you wish to discuss TIP TIG and the easiest way to attain the best possible weld and metallurgical results with any Stainless - Superaustenitic Stainless - Nickel Based Alloys - Duplex Alloys - Inconels - Incoloys - Hasteloys - Stelites - Titanium - Copper - Brass, any Alloy steels or Carbon Steel pipe or fabrication welds, EMail. Ed Craig at ed@tiptigusa.com or nick@tiptigusa.com. If weld cladding is important to your organization we will show you how we can consistently attain the highest possible clad weld quality with the lowest posiible weld dilution and lowest possible weld heat input.

 

A BRIEF DESCRIPTION OF THE PATENT PENDING TIP TIG PROCESS. With the semi-automatic or automated TIP TIG process, the constant fed weld wire is superimposed by a secondary high-speed  oscillation which is generated by the patented TIP TIG, four-roll mechanized drive plate. The TIP TIG wire feed mechanical action creates a vibration on the weld wire. The vibration passes through the weld wire into the weld "agitating the molten TIG weld pool". With the TIP TIG process, Hot Wire current is also added to the agitated weld pool. The increased TIP TIG wire feed rates enables higher than normal TIG weld current. The increased TIP TIG arc - weld energy and disruption of the TIG weld surface creates unique TIG weld dynamics.The change to the TIP TIG weld pool slows down the weld solidification and enlarges the fluid TIG weld area. The weld change enables a typical 100 to 300% increase in TIG wire feed rates. The increased TIP TIG weld quality and faster TIP TIG weld speeds enable a TIG weld quality and productivity never before attained. [1] TIP TIG provides a unique, patent pending Wire Feeder that agitates the weld. [2] TIP TIG provides a Hot Wire Power Source that adds energy to the TIG weld. [3] TIP TIG uses a unique patented Torch that communicates with the weld equipment. [4] TIP TIG uses a 350 - 450 amp, TIG Power Source that has the 4T capability to communicate with the peripheral TIP TIG equipment. The unique patent pending TIP TIG process changes many of the traditional weld rules, weld practices and alloy weld application considerations that for decades have typically been applied to the regular, slow TIG process. TIP TIG enables a dramatic increase in TIG wire feed rates which allows for much faster manual and automated, all position TIG weld travel rates. The increased TIP TIG weld travel rates when combined with Electrode Negative, enable rapid weld heat dissipation in the parts welded. THE REASON ALL ALLOYS BENEFIT FROM THE TIP TIG PROCESS IS IN CONTRAST TO ANY OTHER MANUAL WELD PROCESS, TIP TIG ALWAYS ENABLES THE HIGHEST WELD QUALITY WITH THE LOWEST POSSIBLE WELD HEAT: A ten minute demonstration at the TIP TIG USA. New Jersey facility with either the manual or automated TIP TIG process and you will see why with any steel or alloy weld that the TIP TIG process enables; [] the lowest possible weld joules, [] the highest possible weld quality, [] the least potential for lack of fusion, weld pores or inclusion defects, [] the least sensitivity to alloy weld crack formation, [] the lowest possible weld distortion, [] the lowest possible weld stresses. For those weld shops that are concerned with the weld costs associated with grinding and cleaning welds, as the TIP TIG process produces the lowest weld oxidation potential, this process always produces the cleanest possible welds with the lowest possible weld fumes. IN CONTRAST TO ANY OTHER MANUAL WELD PROCESS, THE TIP TIG PROCESS WILL PROVIDE THE CLEANEST POSSIBLE WELDS THE WILL REQUIRE THE LEAST AMOUNT OF WELD REWORK. In contrast to regular TIG, Hot Wire TIG, Pulsed MIG, Plasma and Flux Cored, the TIP TIG process while providing the lowest weld heat with the highest weld quality will always provide the lowest weld defect potential. When you combine the optimum TIP TIG weld quality with the lowest weld heat potential, the result is defect free welds on weld applications that will have the smallest possible heat affected zones. When you use a weld process that delivers the highest possible weld quality with the lowest possible weld heat, you have the weld solution to every metallurgical weld concern. If your organization is concerned about consistently attaining the best possible charpy impact properties, controlling and providing optimum ferrite or austenite levels, consistently achieving the best possible ductility, fatigue or corrosion properties, or simply providing the lowest possible weld distortion, your company should be evaluating the TIP TIG process. Thanks to the higher TIG weld current, (higher weld energy) and the unique patented "agitated weld pool", in contrast to regular TIG and the automated Hot Wire TIG process, the TIP TIG welds will always provide superior TIG weld fusion. The lowest possible weld oxidation from the faster weld speeds combined with electrode negative and an inert gas results in the cleanest possible welds. These welds will have the lowest weld pore - inclusion defects. The increased energy and agitated weld also dramatically reduces concern with the fusion and pore issues that are generated when welding sluggish alloys such as Duplex - Inconels - Invar - Stainless and high carbon steel applications. TIP TIG ALWAYS ATTAINS THE HIGHEST WELD QUALITY WITH THE BEST POSSIBLE METTALURGICAL PROPERTIES. TIP TIG IS THE ONLY MANUAL - AUTO PROCESS CAPABLE OF CONSISTENTLY PRODUCING ZERO WELD REWORK TIP TIG, USA. is located in Runemeede, New Jersey, (phone 856 312 8164). TIP TIG USA is the exclusive seller of the TIP TIG process in North - South America and Australia. At TIP TIG, we sell and service manual and automated pipe and fabrication equipment. We are a full service shop for the equipment we sell and we have a training and demo facility.

If you are using regular TIG or Pulsed MIG,
don't try to attain this weld quality
with your stainless or alloy gage welds.

Traditional TIG weld speeds on gage parts 3 - 10 inch/min. [] TIP TIG manual gage weld speed > 30 inch/min. [] No weld start or stops for a wire change. [] Cleanest weld you will ever produce. [] Lowest weld distortion you will ever attain. [] No concerns for defects or fumes.

There are corporate executives and engineers that work in the oil, power and defense industries that will frequently complain about weld rework and weld productivity costs, and then lament on the global shortage of skilled pipe welders. Other engineering or manufacturing executives will wait patently at their plants for salesman to show them the latest, useless bells and whistles on new MIG - TIG equipment. And at least twice a year they will watch a gas salesman demo another magic, ineffective three part gas mix. While some global executives lament over their common, ongoing weld quality - productivity concerns, others will rise to their weld quality and productivity challenges, and search for new weld technology that can provide weld cost benefits for their organizations. TIP TIG is a small company. There will be no TIP TIG salesman visiting your facility to sell you on this important new process. If you are interested in a weld process technology that will provide instant weld solutions to most common weld problems, a process that will always provide provide dramatic weld cost savings for your organization, you will have to do what many major global corporations have already done, and visit our New Jersey facility or send us weld samples. A few of the companies who purchased the TIP TIG process or attended the TIP TIG work shops. EXON - HALIBURTON - AREVA - WESTINGHOUSE - BECHTEL - FLUOR - ROLLS ROYCE - WELDING SERVICES / AQUILEX - NORTHROP GRUMMAN - SIEMENS - NOOTER - TI-FAB - DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE - TRIUMPH FABRICATIONS - ENERFAB - DIAMOND POWER - BODY COTE - SPACEX - KELLY CONSTRUCTION- There is extensive TIP TIG weld data available at this site, however the bottom line is this. In contrast to the regular TIG process, TIP TIG requires less skills, produces superior weld and metallurgical properties, dramatically increase either manual - automated TIG weld production and TIP TIG reduces the need for weld cleaning fume extraction equipment. 2011: TIP TIG USA EXPORTS TIP TIG WELD EQUIPMENT AND WELD TECHNOLOGY TO OIL COMPANY IN CHINA: The China National Offshore Oil Corporation, (CNOOC Ltd) is China's largest offshore oil and gas producer. During 2010, CNOOC successfully expanded its business to South America and the Middle East. In 2010, CNOOC  revenue rose 74% while its net profit rose to  $8.03 billion US dollars. 2011. CNOOC had weld concerns in China with the qualification of costly, manual and automated offshore, barge pipe welds. The welds were made on ID, inconel clad sub sea pipe joints. The 5G pipe welds were made on a ship that fed pipe from an oil platform to land. This sub sea pipe line was approx. 20 miles in length. For the ID, inconel clad pipe welds, CNOOC engineers had tried regular TIG and the Pulsed MIG process. The engineers had access to the most costly, sophisticated global weld equipment available. The weld equipment and processes evaluated could not consistently attain the clad weld quality on the pipe ends. With the TIG clad welds there was excess heat issues and the 5 G TIG welds were simply too slow. The pulsed MIG process was incapable of meeting the 100% x-ray pipe welds and ID inconel clad welds. As zero weld rework was a requirement for this project and regular processes were incapable of meeting the weld quality - productivity goals, CNOOC turned to TIP TIG USA for the manual and automated weld solutions. With two weeks of testing at the TIP TIG USA facility, TIP TIG proved it could consistently achieve the desired 100% X-Ray, zero percent manual - auto weld quality and production requirements for the 5G welds. CNOOC quickly placed an order to TIP TIG USA for it's manual- automated TIP TIG weld equipment. TIP TIG provided training, the weld procedures and the manual - automated equipment for this multi-million dollar project.

BOTH THE REGULAR TIG & PULSED MIG PROCESSES FAILED TO MEET THE WELD QUALITY - PRODUCTIVITY REQUIREMENTS FOR THESE SUB SEA PIPE WELDS. TIP TIG provides the required weld quality and productivity desired by CNOOC. It would take 6 regular TIG welders to achieve the hourly production rate of these two COONC manual pipe welders. These welders are using TIP TIG to weld the inconel ID clad sub sea pipes welds made on a ship at sea. With the 100% X-Ray requirenments, the TIP TIG, process attained zero defects.

 

This CNOOC sub sea pipe was approx. 20 miles long with small length sections. The pipe created a welding challenge for the Inconel circumferential welds and for the pipe ends ID which which were clad weld. Note the ease the two TIP TIG welders work together on the pipe joint. One or two hands on the torch, no foot control, no grinding, no spatter, no smoke. In contrast to regular TIG, the benefits are numerous from the higher energy, TIP TIG inconel welds. Dramatic increase in weld productivity and much faster than any weld automation. Faster weld speeds with EN polarity enable the lowest oxidizing, the cleanest welds and the smallest HAZ. The added weld energy combined with the TIP TIG weld agitation means no sluggish alloy concerns, superior weld fusion, lowest weld porosity. The TIP TIG process also enables reduced groove dimensions that further dramatically reduced the weld labor and weld consumables costs.

CNOOC China gets the TIP TIG process ready for it's pipe project. CNOOC has access to the world's lowest cost labor, however for this critical, sub sea weld application this tech savvy corporation knew it required the highest first time weld quality for this complex, costly alloy application. Ship pipe welds for sub sea applications are some of the world's mostly costly welds as the ships daily fees can average around $500.000 a day. The CNOOC engineers had a choice of any global manual - automated weld process and weld equipment. After trying regular TIG and Hot Wire TIG along with the most sophisticated available Pulsed MIG equipment for both it's manual - automated pipe and clad welds, CNOOC selected the TIP TIG process to meet it's production and 100% x-ray requirements..

 

The TIP TIG manual, all position, pipe root - fill welds and the automated TIP TIG clad
welds and mechanical properties were superior to that attained
with any other process including regular TIG, Hot Wire TIG and Pulsed MIG.

 

CNOOC: TWO TIP TIG SUBSEA INCONEL CLAD LAYERS AT THE PIPE ENDS ID. After the clad welds were made, the pipe ends were machined and 5G, root - fill pass welds were made. The TIP TIG welds you see were untouched, no weld rework was required for the 100% X-Ray welds.

[1] Examine the untouched 2 layer, inconel clad weld quality at the ID pipe ends, a location which is a poor heat sink and subject to excessive weld heat buildup with multi-pass clad welds. Examine with the multi-pass welds the lack of oxidation and exceptional weld cleanliness. CNOOCA also derived extensive cost savings as each TIP TIG welder produced these clad welds 200 - 300% faster than that could be attained from a regular manual TIG welder. After the ID inconel cladding was complete, the pipe ends were machined to a narrow J groove. The open root and the TIP TIG manual pipe 5G welds were made on the ship. No weld rework was required on the 100% X-Ray welds. WITH TIP TIG PIPE WELDS YOU WILL ALWAYS ATTAIN SUPERIOR WELD QUALITY, REQUIRE LESS SKILLS AND USE SIMPLE WELD PROCEDURES. NOTE THE WELD UNIFORMITY, NO SPATTER, NO WELD CLEANING, NO DISTORTION, LOWEST POSSIBLE WELD DILUTION, NO WELD FUME ISSUES AND OF COURSE NO WELD REWORK. TOO VIEW THIS CLAD WELD BEING MADE, VISIT THE PIPE SECTION.

TIP TIG SUBSEA WELDS MADE ON A SHIP BY CNOOC.

Inconel subsea pipe clad with inconel, waiting to be welded with TIP TIG.

Optimum weld quality cannot be determined by weld inspection criteria that requests 10% NDT or by any visual inspection. When "optimum weld quality" is discussed at this site, it refers to the ability of a weld process to meet the ASME Sect 1X requirements necessary to consistently attain defect free welds from 100% X-Ray inspection.

 

A summary of the CNOOC weld challenge. Meet the sub sea pipe weld production schedule and quality requirements necessary for the 100% X Ray inspection with the 5G pipe root - fill pass welds and also for the pipe ID clad welds. The 5G pipe welds were made on a ship that cost approx. $500.000.00 a day to operate. Objective.1. The pipe ID automated Inconel clad welds that were to be machined into a J groove prep weld must be better quality than that attained with manual TIG or any pulsed MIG mode. Also the TIP TIG welds must produce lower weld heat input. Objective.2. The pipe 5G root - inconel fill pass welds must be made with a single weld process and for the 100% x-ray manual or orbital welds, zero percent weld rework must be attained. Objective.3. The pipe multi pass welds must require no cleaning or grinding between each weld pass. Objective.4. The pipe -welds must produce minimal weld fumes. Objective.5. Each pipe weld joint must be made 200 - 300% faster than can be attained with a regular TIG welder. Objective 6. Create Weld Cost Reductions. The company that leased the shop and made the welds, saved millions of dollar by eliminating weld rework, optimizing weld productivity and reducing the time the ship was required for the project. TIP TIG WAS THE LOGICAL SOLUTION FOR THE MANUAL & AUTOMATED PIPE WELDS AND CLAD OPERATION.

TIP TIG, 5G INCONEL, SUBSEA PIPE WELDS:

Note the TIP TIG "manual 5G", inconel weld continuity, uniformity and untouched weld cleanliness.
Only TIP TIG can produce all position, manual pipe welds of this quality.
Imagine what you could do with pipe weld automation when you add TIP TIG.

Welcome to TIP TIG USA. My name is Ed Craig and my wife thinks I spend too much time with this web site. Perhaps you also think there is too much weld info on this web site. Please remember, I have been providing optimum weld process control info for 50 years. During those decades I had to deal with an industry that took 30 years to accept the weld quality and productivity attributes of all position flux cored weld wires. The reason for the slow acceptance of the flux cored consumables was the majority of global weld shops "lacked sufficient data" on the FCAW application merits and lacked the optimum weld settings and techniques. For five decades, I simplified MIG weld data and provided books and process control programs to an industry that lacked optimum weld process data, an industry in which the majority of weld shops "still play around" with their MIG weld controls. Also during those five decades, I visited more than 1000 global weld shops improving their MIG welds by turning the useless, over priced, pulsed MIG modes off and setting optimum, conventional MIG spray and and short circuit settings. For more than two decades I was asked to assist numerous global plants that were getting poor weld performance from their robots. The prime reason for the poor robot weld quality or weld production was the plants lacked MIG weld process control data and expertise. Since the nineteen eighties I have tried to take the BS out out of MIG weld gas selection. I introduced simple two part gas mixes and demonstrated to the plants that the over priced 3 part gas mixes they were using was nothing more than a sales con job, (con jobs are easy on an industry that's reliant on sales advice). So forgive me in a time period in which too many get impatient if they have to read more than a four lines of weld data. I don't intend to wait till I am 80 before the weld industry understands the TIP TIG process. At this site I believe it's my job to present all the TIP TIG versus the traditional weld processes data. For those of you that have questions, feel free to call me anytime at 828 337 2695. Many of you will know me from the 18 years of answering questions in the QA section of the Weld Design and Fabrication Magazine, or perhaps you have read one of my three books or one of my 38 articles on MIG and Flux Cored Weld Process Controls. For those that like Engineering books, perhaps you have read the Weld Section I wrote in that Machinery Handbook that's likely gathering dust on your book shelf. I also wrote the Thermal Cutting Section on Laser-Plasma-Oxy Fuel Cutting, in the ASM Handbook. Ninth Edition. 1988. I have four weld patents in the power and fabrication industries and have in the last four decades provided TIG - MIG and Flux Cored Manual and Robot Weld Process Improvements and Process Control Training programs for close to a 1000 companies in 13 countries. In the last few decades numerous companies around the world have purchased my Manual and Robot, MIG - Flux Cored, Best Weld Practices - Process Control Books or Training Resources available at www.weldreality.com. While assisting a UK sub sea valve manufacturing company called Cameron with their automated Hot Wire TIG inconel, clad valve weld issues, I received information on a new European weld process called TIP TIG. I travelled to Scotland to view the process. During the TIP TIG demo, it took me five minutes to figure out that this process was a dramatic game changer for the global weld industry. A few months later, my business partner Tom O'Malley and I introduced this important weld process to North America. TIP TIG. USA has the exclusive rights for distribution of TIP TIG in North and S. America and Australia. At TIP TIG USA we sell manual and automated weld solutions for all weld applications that require high quality welds. IN AN INDUSTRY THAT RARELY DISCUSSES BEST WELD PRACTICES, WELD PROCESS CONTROLS, OR REAL WORLD WELD COSTS, AN INDUSTRY THAT FOR DECADES HAS USED SALESMANSHIP TO INFLUENCE WELD DECISIONS, YOU WILL FIND SOME WELD DECISION MAKERS HAVE A DIFFICULT TIME DIFFERENTIATING THE COMMON, EXAGERATED WELD EQUIPMENT SALES ADJECTIVES FROM REAL WORLD WELD QUALITY PRODUCTIVITY AND COST BENEFITS. In an industry that used to four common weld processes that have changed little in the last sixty years, it should be no surprise when someone in the weld shop management asks, "why change the way we have always welded"? In an industry that not used to change, achieving optimum weld quality, reducing weld product liability and driving down weld costs should be always be driven by "managers, engineers and supervisors". If you need info on why TIP TIG is superior to the weld processes you are using, check out the manual - automated and pipe sections at this site or call me at 828 337 2695.

AT TIP TIG WE MAKE THIS FUNDAMENTAL PROMISE. WHEN WELDING WITH THE TIP TIG PROCESS YOU SHOULD ALWAYS EXPECT SUPERIOR WELD QUALITY WITH DUPLEX ALLOYS - ALL STAINLESS & NICKEL ALLOYS - HASTELLOYS - CHROME STEELS - INCONELS - INCOLOYS - MONEL ALLOYS - INVARS - KOVARS - STELLITES - TITANIUM - ALL COPPER & BRASS ALLOYS - ALL HIGH STRENGTH CARBON AND ALLOY STEELS - ALL PIPE WELDS AND ALL CAST OR WROUGHT PRODUCTS: The welding proof is always in the manual or automated weld demo. At our New Jersey TIP TIG facility, it will takes us a few minute with a weld demo on any sample you provide to reveal that in contrast to any other available weld process, TIP TIG will always produce superior weld quality.

 

The semi-automatic TIP TIG process will always produce
optimum weld quality with the lowest weld heat and distortion.

ELIMINATE YOUR WELD DISTORTION ISSUES : You need to weld small stainless, inconel, incoloy or any alloy application and weld quality and distortion are prime concerns. Take a look at the above flange which has a double vee groove requiring a full penetration X-Ray weld. The flange has bolt holes and the regular TIG process produced excess weld heat which distorted the flange putting the flange holes out of spec. TIP TIG provided the solution and the TIP TIG is the best possible weld solution for any alloy welds in which distortion is a concern. On the above application, in contrast to regular TIG, the TIP TIG process increased the multi-pass TIG weld speeds by 200% and TIP TIG required 50% less weld passes. TIP TIG produced no distortion, no weld spatter, no weld fumes, and required no weld cleaning.

 

Add the TIP TIG process to our unique automated orbital, robot and ossicilator equipment and
you will have low cost solutions to providing the best possible pipe and clad weld quality.
For info on this product line, call Nick or Ed at 856 312 8164.


TIP TIG automated welds will provide superior weld quality and productivity than any Hot Wire GTAW process.

 

 

The natural manual & automated weld process of choice for the Nuclear Industry is TIP TIG.

In southeastern Washington state, Bechtel National, Inc. is designing, constructing and commissioning the world’s largest radioactive waste treatment plant for the U.S. Department of Energy (DOE). When complete, the Hanford Tank Waste Treatment and Immobilization Plant (WTP) will process and stabilize 56 million gallons of radioactive and chemical waste currently stored at the Hanford Site. The WTP project uses the vitrification technology which involves blending the radioactive waste with glass-forming materials and heating it to 2,100 degrees Fahrenheit (1,149 degrees Celsius). The mixture is then poured into stainless steel canisters to cool and solidify. In this glass form, the waste is stable and impervious to the environment, and its radioactivity will dissipate over hundreds to thousands of years. The WTP Project is equivalent to building two nuclear power plants. The construction site spans 65 acres and includes four major nuclear facilities. Bechtel's subcontractor Intermach. Inc. is using the new TIP TIG process to weld it's 42 - 60 inch thick wall stainless pipe to ASME standards, (see picture below).

 

TIP TIG welding 40 - 60 inch stainless pipe at the Hanford Nuclear facility.

TIP TIG better quality than manual & auto TIG with lower weld heat than TIG.
TIP TIG less smoke than TIG, easier to use than TIG and always
200 - 400% more hourly productivity than TIG.

Optimum weld quality cannot be determined by weld inspection criteria that requests visual inspection or 10% NDT. When "optimum weld quality" is discussed at this site, it means the ability of a weld process to meet the ASME Sect 1X requirements necessary to consistently attain defect free welds subject to 100% X-Rays. Today there is only one manual weld process that can consistently meet the 100% X-Ray or UT weld quality requirements, that weld process is TIP TIG.

TIP TIG & SMALL DIAMETER PIPE WELDS:

Take a look at stainless pipe TIP TIG root and the fill pass. Don't forget with TIP TIG you can dramatically reduce the pipe groove dimensions. Apart from the increased weld travel rates with TIP TIG you will also require less fill passes and the consumables required will also be dramatically reduced.

With the semi-automatic process combined with any rotary positioner you have the best and lowest cost weld automation. With TIP TIG you reduce the manual weld skills required to feed a TIG wire and don't forget you eliminate the need for a foot control. For the TIP TIG pipe fill passes on this thin gage pipe you will be welding approx. 200 to 250%. faster than a regular TIG welder and the weld quality will always be superior.

 

HOW IMPORTANT IS IT FOR YOUR ORGANIZATION TO CONSISTENTLY DELIVER
OPTIMUM WELD QUALITY WITH THE LOWEST POSSIBLE WELD HEAT INPUT?

WHEN WELDING ALLOYS AND CODE QUALITY WELDS, ANY WELD COMPANY SHOULD WANT TO SELECT A WELD PROCESS THAT CAN CONSISTENTLY DELIVER THE BEST POSIBLE ALL POSITION WELD QUALITY WITH THE LOWEST POSSIBLE WELD HEAT INPUT. With the next code weld application coming up, many companies will be considering the regular TIG - Hot and Cold Wire TIG - Pulsed MIG or the Plasma process, however the fundamental weld fact is this, none of these weld processes can enable the manual or automated optimum weld quality, optimum mechanicals or optimum corrosion properties that will be consistently attained with the TIP TIG process. If you are welding P91 - Super Duplex, Monel 400 Stelite or Titanium, attaining optimum impacts, optimum strength or optimum corrosion properties, or achieving the lowest weld distortion, avoiding cracks or consistently attaining the desired metallurgical composition becomes a simple task with the TIP TIG process. With TIP TIG you can take any complex alloy weld application and make it look simple as revealed with TIP TIG welding titanium in the unique video below. Scroll down to watch the many videos that reveal what the regular TIG and Pulsed MIG weld processes cannot do. TIP TIG IS THE ONLY MANUAL WELD PROCESS CAPABLE OF WELDING TITANIUM & ATTAINING OPTIMUM WELD QUALITY "WITHOUT USING A GAS TRAILING SHIELD". You can employ manual welders with the highest pipe or fabrication weld skills, however the weld process you are using at this time will have it's influence on the weld quality attained. In the last 50 years I have been in weld shops I never met an experienced weld shop manager that would have had any expectation to consistently attain zero percent weld rework on manual welds that were 100% tested with X-Rays or UT. The TIP TIG process should change management weld quality expectations. Using either the manual or automated TIP TIG process, your weld shop should have reasonable expectations to consistently attain "zero percent weld rework" with any all position, code quality welds on any alloy weld or clad applications. Note: If you believe the TIP TIG quality and production claims sounds to good to be true, you can bring or send your parts or samples to our New Jersey facility. We will provide you with a video of us welding your parts, or if you pay us a visit and you understand welding, with a few minutes with the TIP TIG process we will show you a level of TIG weld quality and productivity that has never been attained in your organization. THOSE INTERESTED IN WELD COST REDUCTION: With TIP TIG, the increased TIG weld deposition rates - the faster TIG weld speeds - attaining the lowest possible weld defects - enabling a dramatic reductions in groove dimensions - the requirements for less weld skills and the lower TIG gas and wire costs, all combine for dramatic weld cost reductions for any weld organization. Managers and supervisors, if reducing weld costs is important to your organization, it's a fundamental fact that TIP TIG will dramatically ower your weld rework costs and each hour, your manual TIP TIG welders will typically provide an increase of 100 to 400% weld production for all pipe and plate welds and for all gage parts > 1/16 (> 1.6mm.) Note: To see the extraordinary improvements in both TIG weld quality and productivity, view the many videos on this site and the more than 70 TIP TIG videos on U-Tube. Take note of the weld appearance, the weld cleanliness, the small HAZ, the weld sizes and the recorded arc on times. For manual "pipe weld cost differences" between the regular the TIG process and TIP TIG, please visit the pipe and manual sections.   FOR THOSE WELD SHOPS INTERESTED IN APPLYING EFFECTIVE MANUAL WELD PROCESS CONTROLS. In contrast to regular TIG and Pulsed MIG, the TIP TIG process enables greater all position, weld process controls. As TIP TIG requires 3 or 4 settings for all weld applications the TIP TIG weld procedures are easier to establish. There are few weld managers that would want to weld an all position application such as a 30 foot diameter, one inch wall, inconel or stainless vessel using the regular manual TIG process. The managers would be aware that the typical TIG slow weld speeds would be approx. 2 to 4 inch-min. The same managers would be aware that if they used the pulsed MIG process and 100% X-Ray was required, they would likely find lack of weld fusion and unacceptable porosity defects. In contrast, from a vessel root to the fill and cap passes, the semi automatic and automated TIP TIG process is productive and cost effective and frequently used on large applications and fabrications that were welded with the SAW process. TIP TIG was used for all the welds on the vessel shown right. From a process control perspective, QA managers should note that TIP TIG is a "semi-automatic" TIG process. TIP TIG enables good deposition rates and drives constant manual weld speeds. The TIP TIG wire is always directed at the TIG arc sweet spot providing weld continuity and uniform melting of the weld consumable. Put the TIP TIG process in the "one or two hands" of a decent welder and he will provide better weld quality than attained with any other manual or automated weld process. On a vessel like the one shown above, the TIP TIG groove, fill pass weld deposition rates would typically be 200 to 400% greater than that attained with regular TIG. With TIP TIG the increased weld speeds result in the lowest weld heat (lowest distortion - best mechanicals) and don't forget the lowest weld fumes. FORGET THOSE CONVENTIONAL, OVERSIZE WELD PREP DIMENSIONS: With TIP TIG you have the capability to dramatically reduce the standard vee or J groove dimensions, which when combined with the increased TIP weld productivity and ability to produce zero weld rework, provides tremendous weld cost benefits for any code weld project. SIMPLIFY PIPE AND VESSEL WELD PROCEDURES: For the weld shops that have file cabinets full of multi-process, complex weld procedures, please note that TIP TIG will simplify the required weld procedures. For example all the alloy welds required in the construction of a Nuclear Power plant could be achieved with three or four TIP TIG weld procedures. There is no other weld process that will enable the weld quality Process Controls that TIP TIG can bring to any manual or automated weld. For those interested in Welder Qualification with the TIP TIG process. Please note if your welders are qualified for regular manual or automated TIG, with the ASME code they are also qualified for TIP TIG. WELD PORE DEFECTS & UNECESSARY WELD GRINDING & CLEANING. In contrast to all other processes, TIP TIG produces the cleanest possible welds from the lowest weld heat and inert ga. The TIP TIG welds will have the lowest "weld oxide reactivity". With multi pass alloy welds and the TIP TIG process, you should not require a grinder and minimal to zero brushing will be required.

 

 

Major USA union leads the way in weld technology and
installs TIP TIG at all it's pipe weld training facilities.

Tom O'Malley from TIP TIG is training the UA pipe welders on the TIP TIG process at the
United Association, Plumbers, Fitters, Welders HVAC Tech's Training Center.

In 2011 the UA union management created a mandate to train all it's pipe welders on the TIP TIG process. While
the regular TIG process took two hands and a foot control and too many arc start - stops, with TIP TIG the UA
pipe welders can now focus entirely on their weld technique and on what's going on in the weld pool.

Westinghouse welder using TIP TIG. The manual TIP TIG wire feed rate enabled 300 - 400% more 5G weld than most TIG pipe welders can produce each hour. Westinghouse management is aware they are getting better pipe weld quality than the regular TIG process and their welders are aware that without the need to feed a wire or operate a foot control they have a process which is much comfortable to use.

 

Thick wall pipe (> 8 mm) and large diameter pipe (> 20 cm). In contrast to regular TIG, with TIP TIG you should typically attain 200 - 400 % more pipe fill pass weld production each hour. Thinner wall pipe and smaller diameter pipes. With TIP TIG you will typically attain 100 to 200% more weld.

TIP TIG PIPE WELD PRODUCTION - COST BENEFITS. In contrast to manual TIG, using TIP TIG the Westinghouse manual pipe welders will typically provide 200 - 300% more pipe weld production each hour. The TIP TIG process also enables an increase in hourly arc on time and decrease in pipe vee or J groove dimensions. With TIP TIG, your weld wire reels will cost less than TIG wire and you will dramatically reduce the weld gas costs. TIP TIG PIPE WELD QUALITY BENEFITS. Higher TIP TIG wire feed rates enable increased weld current which combined with the smaller diameter TIP TIG weld wires and Hot Wire current, enables increased weld energy. The faster TIP TIG pipe manual weld speeds lower the weld oxidation potential providing cleaner welds which is especially beneficial for multi-pass pipe welds. Combine the TIP TIG increased weld energy and lower oxidation benefits with the unique agitated TIP TIG weld pool which slows the weld solidification. With TIP TIG you always should produce pipe welds with improved side wall fusion and the welds should have the lowest weld porosity and weld inclusion content. THE CONVENTIONAL HOT AND COLD WIRE TIG PROCESS VERSUS TIP TIG. For decades, the little changed, regular TIG weld process has been considered the weld process that will deliver the best quality for most manual welds, while the conventional Hot - Cold Wire TIG process would be considered the process of choice for optimum, "automated" weld quality. The conventional automated Hot Wire (HW) TIG process typically provides 60 to 100 amps to a constant fed weld wire that is fed into the TIG arc. This process can be a highly sensitive when used on "low to moderate weld current applications" such as vertical up or over head pipe or clad welds. With these applications the sensitive TIG arc length is typically monitored with an Arc Voltage Control (AVC) and the wire feed rates that can be used are restricted. Note: Due to the HW "arc length sensitivity" and requirement for an AVC, the Hot Wire TIG process has been rarely suited for manual TIG welds. When the regular automatic or manual Cold Wire (CW) TIG process is used, (CW on right), the CW torch movements and wire feed rate utilized will be highly restricted. The CW process will be very sensitive to the welder's torch manipulations as typical when walking the cup. NOTE: A PRIME ISSUE WITH THE COLD WIRE PROCESS IS THE CW WELD DEPOSITION IS APPROX. THE SAME AS THE REGULAR MANUAL TIG PROCESS. THE BOTTOM LINE, IN CONTRAST TO CONVENTIONAL TIG THERE ARE NO WELD QUALITY OR WELD PRODUCTIVITY BENEFITS. The manual and automated average CW TIG weld deposition rates are typically no more 1 lb/hr, or approx. 0.3 lbs/hr with 20 minute arc on time. The semi-automatic CW process, provides no more weld deposition than the wire feed rates generated by any manual, regular TIG welder feeding a weld wire with their hand. TIP TIG REDUCES THE COMMON AUTOMATED CONCERN WITH "TIG ARC LENGTH SENSITIVITY". In contrast to HW TIG, the TIP TIG process can be used on many automated applications without the use of an Arc Voltage Control. TIP TIG is the only manual semi-automatic TIG process that can weld any all position weld on any application, any thickness and any alloy without the use of an AVC. Note: For those considering the Pulsed MIG process for code quality welds, scroll down to find out why Pulsed MIG can never attain the all position, alloy weld quality attained with the TIP TIG process.

 

 

The Achilles Heel of Regular TIG: When we talk about the evolution of the regular TIG process, it's important to note the following. When welding steels and alloy steels, a 1961 conventional Constant Current TIG power source will produce the same weld quality and productivity than that attained with the most costly, sophisticated electronic TIG equipment that you could purchase in 2011. The primary issue with the regular TIG process. Over five decades, the majority of electrical and electronic changes with TIG equipment has had minimum impact on the Achilles heel of the TIG process which was the "rapid freeze, small weld pool". Regular TIG = Rapid Freeze Weld, = Small Fluid Weld Area, = Slow Weld Speeds, = High Part Heat, = Excess Weld Start - Stops, = Highest Weld Skills. Depending on the weld size, the regular TIG welder typically has to start and stop every three to ten inches of weld while they provide a new length of weld wire. The manual TIG process is the only process that requires the use of two hands and sometimes a foot control requiring the highest manual skills. The rapid freeze TIG weld, the excess weld part heat, the many weld starts and stops, the variable weld current from a foot control and the high skill requirements that change from one welder to another, are the primary factors that will influence manual TIG weld quality. Weld processes and weld quality fact: The regular manual TIG - Pulsed MIG - All MIG nodes and Flux Cored processes will typically not consistently meet 100% code, all position weld quality requirements with alloy applications, however as all weld personnel are aware, the TIG weld process will deliver far superior weld quality than the other processes mentioned. With this in mind It's logical that any major improvements with the TIG process, improvement that can provide superior weld quality or increased productivity, should have great interest to those weld shops dealing with code quality welds.

 

A comparison of TIP TIG versus the CMT and Pulsed MIG processes.
Reference all steels and alloy applications, excluding aluminum.

Weld Process Benefits	Manual TIP TIG Process	Manual CMT - Pulsed MIG Process
weld application range	Fabrication, 14 gage to any thickness. Pipe welds, and size optimum root and fill passes.	CMT fusion concerns on parts > 4 mm. Pulsed MIG, too hot for specific gage applications < 3mm and fusion concerns > 5mm.
weld positions	Optimum welds any weld position.	Pulsed vert up may result in lack of weld fusion > 4 mm
weld fusion	Superior fusion than any weld process.	Both CMT and pulsed MIG will produce inferior weld fusion, especially on parts > 4 mm.
weld porosity	With the unique agitated TIP TIG welds and higher energy TIG weld, plus no oxidizing gases, TIP TIG always produces lowest porosity	Both CMT and pulsed MIG provide lower weld energy welds and use reactive gas mixes that contribute to porosity. The porosity potential dramatically increases with sluggish alloys.
weld distortion	As EN polarity is used with higher TIG speeds, the TIP TIG process provides the lowest distortion.	Both CMT and pulsed MIG use Reverse Polarity which maintains and focuses the arc energy in the plasma creating larger HAZ and increased distortion potential.
clad welds	Lowest weld dilution potential with higher clad weld quality than either CMT or Pulsed MIG	CMT also enables low dilution (with inferior clad weld quality). Pulsed MIG higher dilution and poor clad weld quality.
weld mechanical properties	Lowest weld joules and widest weld joules range should always ensure superior mechanicals	Weld Mechanicals are influenced by the weld jules input and weld joules range. Both CMT and pulsed MIG cannot attain the low weld joules or the weld joules range provided by TIP TIG
weld spatter	None with TIP TIG.	Low level to miniscule spatter with both processes.
weld tie ins	Superior start stops and superior multi-pass welds due to TIG controls, agitated higher energy welds.	Inferior start stops and inconsistent fusion on with multi-pass welds, made worse when sluggish alloys are welded
weld transfer and arc stability	In contrast to all other weld processes, TIP TIG provides the most stable weld transfer and weld arc stability.	Thanks to electronic bells and whistles and peak to back ground parameter changes, both these processes have inferior weld transfer and inferior arc stability than TIP TIG.
weld cracks	Lowest potential for weld cracks on any alloys.	CMT low potential. Pulsed MIG higher potential for cracks.
wire stickout influence	Has no influence	Both CMT and any pulsed MIG welds are greatly influenced by small wire stick out changes
weld gases	Only requires one gas argon	Uses dufferent gas mixes and welds influenced by the the reactivity of the gases which are not inert
weld cleaning and weld fumes	TIP TIG always requires the lowest weld cleaning and produces the lowest weld fumes	Reactive gas mixes and higher joules will typically mean CMT will provide better results than pulsed, however the TIP TIG process will always provide the best manual weld results.

 

 

It's TIP TIG, pull up a stool, relax, and then switch on the music.

[] It's TIP TIG, forget that arthritic pain in your left hand, you don't have to feed a TIG weld wire. [] It's TIP TIG, you no longer have to worry about leg cramps? you don'tneed a foot control. [] It's TIP TIG, don't worry about stainless grinding dust, as no grinding or cleaning is required. [] It's TIP TIG, don't worry about weld fumes as TIP TIG always produces the lowest possible fumes.

TIP TIG welding High Strength - Low Alloy steel parts. It's your choice, use the TIP TIG process, or ask why? [] Why use regular TIG and take 200 - 300% longer? [] Why super heat a weld part that has been heat treated to attain high strength? [] Why use pulsed MIG, provide excess heat and possibly get lack of fusion & porosity? [] Why use any weld process that causes excess weld distortion or shrinkage concerns? [] Why use a process that struggles to attain optimum charpy - metallurgical properties? [] Why deal with weld spatter - weld grinding - and multi pass weld cleaning? [] Why deal with high pre-heats when with TIP TIG they typically will not be required? [] Why use processes that require large grooves when you could use smaller grooves? [] Why use a process that requires higher weld skills? [] Why be concerned with weld fumes?

Siegfried Plasch is a European weld engineer. Siegfried, (center in photo) invented the patented TIP TIG process. Siegfried developed a unique wire feed unit for the TIG process. With the TIP TIG feeder, the weld wire from the reel is superimposed by a secondary high-speed oscillation generated by the four-roll drive plate. The mechanical action generated on the constant fed weld wire creates a vibration in the wire. The vibration passes through the TIG weld wire and agitates the molten weld pool. With the TIP TIG process, Hot Wire current is also added to the wire action. The result is the TIP TIG process adds both energy and motion to the TIG weld. The TIP TIG increased weld energy and motion dramatically changes the regular TIG weld pool dynamics, increasing the fluid weld area and prolonging the TIG weld solidification. The change in the TIG weld dynamics reduces concerns for sluggish alloys, allows for  an improvement in TIG weld quality and allows for a 50 to 400%  increase in manual and automated TIG wire feed rates. The faster TIP TIG weld travel rates result in a dramatic reduction in TIG weld heat input which again adds to the TIG weld quality and provides metallurgical improvements. At the 2008 Essen Weld Show, TIP TIG received the prestigious award for the show's most innovative weld process. TIP TIG USA (www.tiptigusa.com) is responsible for all the TIP TIG machine sales in North and South America and Australia.

 

 

TIP TIG, a great manual - automated weld solution for alloy and carbon steel Thin Gage welds.

TIP TIG AND THIN GAGE WELD APPLICATIONS:

COMMON WELD ISSUES WHEN WELDING THIN GAGE APPLICATIONS. With gage welds, the weld shop will be aware of the lack of weld continuity with the weld appearance that comes from the TIG weld start - stops and weld heat build up. The weld shop will also be concerned with part distortion and weld burn through concerns and the excess weld oxidation that comes from the slow weld speeds. It's a fundamental fact that with gage welds there is often more weld costs associated with grinding and cleaning then there is with the cost of welding. Regular Short Circuit MIG - Pulsed MIG and Flux Cored welds on gage parts will often produce over size welds - produce excess distortion - result in weld burn through - produce excess oxidation - provide weld Irregularities, porosity, poor weld tie ins and spatter. TIP TIG and THIN GAGE WELDS: Gage weld benefits are attained from the TIP TIG process when manual welding > 16 gage (> 0.060) metals. With any alloy gage welds, the TIP TIG process should always provide the highest possible weld quality, enable the lowest weld cleaning and produce the least distortion. TIP TIG will depending on the gage applications welded, enable manual and automated weld speeds that will typically be 200 - 500% faster than regular TIG. Automated gage weld benefits: when used with weld automation TIP TIG provides many high weld speed, low weld heat input alloy weld benefits on parts as thin as 1.2 mm.

 

DO YOU WELD THIN > 16 GAGE STAINLESS OR ALLOY PARTS?
YOU NOW HAVE THE OPPORTUNITY TO REDUCE DISTORTION - GRINDING - CLEANING:

Don't try the following in your weld shop. Produce a manual 1/8 (3 mm) fillet weld on 14 gage (approx. 0.080) stainless or on any alloy parts with your Pulsed MIG or TIG process, and do that manual weld at > 35 inch -min, produce zero spatter, produce no smoke, produce welds that require no grinding - weld cleaning and welds that will provide the lowest possible weld distortion. To see this TIP TIG weld, view video below.

Watch the regular TIG welder (left below) weld the 14 gage stainless welds at a typical travel rate of 6 to 10 inch inch/min. Compare the TIG weld speeds with the manual TIP TIG welder doing the same welds at 35 to 45 inch/min.

Regular TIG versus TIP TIG for Gage parts.

Take note of the gage weld quality - cleanliness and the U-TUBE arc on times for these two common gage stainless welds.
Regular TIG 1/8 Fillet. Depending on the skill levels, with regular TIG you would take 1 to 2.5 minutes,	TIP TIG 1/8 Fillet: This weld takes approx. 15 sec's and provides superior quality than regular TIG. TIP TIG enables less grinding, less weld cleaning and less distortion.
Manual regular TIG weld travel rates on 14 to 10 gage are typically 6 - 10 inch/min with frequent arc starts / stops. Usual TIG concerns, distortion and lack of weld continuity and uniformity with high costs associated with grinding and oxide removal.	TIP TIG weld time for this 12 inch, 1/8 fillet weld is approx. 15 seconds - weld travel rate approx. 45 inch- min. With TIP TIG less skills required, better quality than regular TIG with lower weld heat, no weld fumes no grinding - cleaning

 

Questions. In a time in which there is a global shortage of skilled TIG welders, if you had to train someone to make quality, stainless gage welds similar to the above weld; [] Which process, regular TIG or TIP TIG would be easier to use? [] Which process will produce superior weld quality with lower distortion? [] Which process will dramatically lower the labor - cleaning - rework costs?

 

The Northrop Grumman Weld Eng who attended a TIP TIG work shop wanted a solution to his weld problem. The engineer was required to produce small alloy, 3 mm fillet welds with no weld defects and minimum weld distortion. The welds would be the length of an Aircraft Carrier.

 

When you need to produce a 1/8 (3 mm) fillet weld, 1000 plus feet long and produce a weld with the highest weld quality and the lowest distortion, you can try pulsed MIG or regular TIG, however there is only one manual or automated weld process that will provide the weld results you desire without weld distortion concerns, that process is called TIP TIG.	The Northrop Grumman engineer asked us to produce a 2.5 - 3 mm TIP TIG stainless fillet with a small HAZ. Note the weld color from the low weld heat and note the small HAZ with the above video.

 

 

EXAMINE THE WELD EQUIPMENT - CONSUMABLES IN YOUR ORGANIZATION. WHAT REAL WORLDS WELD BENEFITS ARE YOU ATTAINING? For that pipe root or alloy gage weld you consider SMAW, regular TIG, MIG CMT, MIG RMD or Short Circuit. For the pipe fill or fabrication welds you consider SMAW, Pulsed MIG, MIG Spray, Metal Cored or Flux Cored. Think about the weld equipment and consumables required, the weld process knowledge required, the weld qualification and complex procedures required. The irony with any of the weld processes mentioned is there will be no guarantees that ensure you meet 100% X-Ray requirements. You will have quality issues. You will have distortion issues. You will have metallurgical concerns. You will have weld cleaning and weld fumes issues. Now take a look at what one process called TIP TIG will provide. [a] TIP TIG, always superior weld quality than regular manual TIG - Pulsed MIG and auto Hot Wire TIG. [b] TIP TIG reduced manual TIG skills for all position pipe and fabrication welds. [c] TIP TIG reduces TIG weld labor costs in the 100 - 300% range. [d] TIP TIG one weld gas and in contrast to TIG, TIP TIG provides a dramatic reduction in weld consumable costs. [e] TIP TIG welds require three simple procedures which simplifies weld qualification and procedures. [f] TIP TIG eliminates the need for "multi - processes" often used with pipe welds. [g] TIP TIG always provides the best possible mechanical and corrosion properties with all alloys. [h] TIP TIG in contrast to any process enables superior weld fusion with less porosity on all sluggish alloys. [i] TIP TIG has the least potential for cracks with any alloys. [j] TIP TIG produces the lowest weld fumes. [k] TIP TIG eliminates the need for grinding and reduces weld cleaning on all steels. TIP TIG is not about useless three part gas mixes, (Ed was a key member that wrote the AWS MIG Gas Specifications) or about overpriced weld equipment filled with unnecessary, costly electronic bells and whistles. TIP TIG is a logical, mechanical, engineered solution developed to improve the weld dynamics that occurs with both the regular manual TIG process and the automated Hot Wire TIG processes.

INDUSTRY OPPORTUNITIES FROM THE TIP TIG PROCESS: In the next decade, the companies that are capable of consistently producing optimum code quality welds will see weld growth opportunities in the following industries; [1] Power Plants, construction and repairs. [2] Oil & Nat Gas, numerous applications. [3] Defense and Aerospace applications. [4] Medical industry applications. [5] Electronic industry applications. [6] Food processing equipment. A common denominator with the above growth industries is the fundamental necessity for weld decision makers to deliver consistent, optimum quality welds and minimize weld rework on costly code weld alloy applications. To achieve this weld task, many weld companies will consider four common weld processes. [1] The hundred year old SMAW (stick) process. [2] The sixty year plus year TIG process. [3] The thirty year plus Pulsed MIG process. [4] The forty year plus Gas Shielded Flux Cored process. Of course they may also consider the following; MIG SHORT CIRCUIT - MIG SPRAY - MIG RMD - MIG STT - MIG CMT - METAL CORED: WITH THE TIP TIG PROCESS YOU NO LONGER NEED MULTI-WELD PROCESSES FOR YOUR PIPE - VESSEL- PLATE ALL POSITION WELD APPLICATIONS. To produce manual, code quality, carbon steel or alloy steel pipe root - fill pass welds, many weld shops are required to utilize multi-weld processes such as MIG STT - RMD - CMT - SC or regular TIG - SMAW for the root and Pulsed Mig or Flux Cored for the fill pass welds. The irony with the SMAW - MIG - FCAW processes, is no matter what the skill levels are with the pipe welders, these weld processes, simply do not have the potential to consistently produce 100% X-Ray weld quality, especially when all position welds on "sluggish alloys" are required. When you add unnecessary weld processes to a weld shop, you raise the level of required weld process control expertise, (an expertise often lacking). Your weld personnel will also require unique skills for each process utilized and multi processes add to the complexity of the required procedures and weld qualifications. In an industry that rarely focuses on Manual Weld Process Controls, you may not want to ask the following fundamental MIG weld question . MIG Weld Question: Using an 0.035 (0.9mm) MIG wire and a common argon - 15 to 20% CO2 mix, (two gas mixes Ed introduced to the USA). What is the weld voltage - wire feed setting in inch/min and weld amps in which the the Short Circuit mode changes to Spray Transfer? You know with this MIG question, if you asked five welders in any global weld shop, you would get five very different answers. If you believe weld personnel should not be playing around with weld controls on a fifty year old process and that your weld personnel should have fundamental MIG and Flux Cored Weld Process Control knowledge, please visit my web site www.weldreality.com. Click here to attain the Best Weld Practices - Weld Process Controls training resources, these programs will greatly enhance your manual - robot MIG - FCAW weld quality - productivity. To attain the best weld quality - productivity potential from any weld process requires; [1] Weld Equipment - Consumable knowledge. [2] Weld Process Control expertise. [3] Weld Best Practice knowledge. Unfortunately some of the above three requirements are frequently lacking. Note: It's important that weld management remember that Irrespective of the weld personnel's weld skills and weld process expertise, the root cause of many weld defects can be traced to the weld process or consumable selected. REGULAR TIG: If you are interested in the TIP TIG weld application potential, its important to understand the weld differences between the regular TIG process and TIP TIG. Of the available common weld processes, the regular TIG process has been considered the weld process of choice, however the regular manual TIG process is also noted for; [1] the high weld skills required, [2] the lack of weld continuity, [3] the lack of weld uniformity, [4] distortion concerns, [5] the low TIG weld deposition rates that result in very slow weld speeds and high weld heat input. The high TIG weld heat can negatively impact the weld and part mechanical and corrosion properties and also influence the weld oxidation potential. Slow manual regular TIG weld speeds are primarily influenced by the following factors. [] The narrow TIG plasma zone and the resulting small fluid, rapid freeze weld area restrict the wire feed potential. [] As a regular TIG welder would lack the ability to feed a "small diameter wire" at the wire feed speeds required, the welders have to use large TIG weld wires, typically 1/16 - 1/8 (1.6 - 3.2 mm). [] The typical all position TIG weld current utilized in combination with the large weld wire diameters and small fluid weld pool decrease the receptivity for the TIG manual welder to attain all position deposition rates above one pound an hour. [] Note the TIG 50% - 50% distribution of the TIG arc plasma energy divided between the weld and the large wire. The bottom line with all position regular TIG welds is you have a sensitive arc length process that generates a rapid freeze, small fluid weld area that's highly sensitive to the amount of weld wire that can be delivered.

CONSIDER THE TWO SIDED TIP TIG METHOD FOR VESSEL, TANKS OR PLATE OPEN ROOTS: No back purging gases. No grinding. No gouging and no root weld repairs.

The two side TIP TIG root technique is a great cost saving solution for many open or closed root applications and don't forget with TIP TIG you should reduce the weld groove dimensions.

WHY DOES A LOWER CURRENT TIG WELD OFTEN APPEAR TO PRODUCE MORE WELD HEAT IN THE PART BEING WELDED THAN A MUCH HIGHER CURRENT MIG OR FLUX CORED WELD? With the Electrode Positive (EP) MIG and Flux Cored process, the majority of the weld heat is concentrated in the plasma at the weld wire tip. EP enables sufficient energy to melt the rapid, constant fed weld wire. The localized and concentrated heat in the electrode positive MIG - FCAW arc plasma will often result in welds with large heat affected zones which when combined with weld solidification shrinkage can result in excessive distortion. In contrast to the electrode positive MIG and Flux Cored process, the TIG process provides a higher arc temperature. WIth the electrode negative (EN) TIG and TIP TIG process, you have a process in which the electrons travel from the tungsten tip to the positive work. The EN electron direction means the majority of the TIG heat is delivered and dispursed throuh the base metal. As a manual TIG welder would lack the abilty to consistently feed a small diameter at the required wire feed input, the typical TIG wire sizes used is > 1.6mm. The TIG arc creates a plasma (ionized gas). The narrow plasma heat melts the base metal and creates a small fluid weld area. When the large diameter TIG weld wire is dipped into the weld a good portion of the TIG plasma energy is absorbed by the large weld wire. The TIG weld has a small, rapid freeze fluid weld area and the majority of the TIG arc energy is in the absorbtion of the the weld wire and the diffusion of the weld heat into the part being welded. A reasonable question any welder would ask. "With the majority of the TIG weld heat dispursed in the work, why does the regular TIG process appear to produce as much or more weld heat in the part than a MIG or flux cored weld creates"? THE HIGH WELD HEAT IN MOST TIG WELD PARTS IS A DIRECT RESULT OF LOW TIG WELD DEPOSITION RATES: At low to moderate weld current typically less than 250 amps, manual TIG weld deposition rates based on a 60 minute arc on time are typically in the range of 0.7 - 1 lb/hr. The low manual TIG deposition rates results in low weld travel speeds usually in the range of 2 to 8 inch/min. In contrast, MIG - FCAW will typically deposit 8 to 12 times more weld producing manual weld speeds which are usually in the range of 10 - 40 inch/min range. Depending on the weld application, weld size - weld length and the part thickness, the low TIG weld speeds can produce high heat to the welds and to the parts heat affected zones. Depending on the alloys welded or the weld wire used, excess TIG weld heat can be the prime cause of cracks, reductions in weld / part strength - cause corrosion issues, provide excess weld oxidation, create excess stresses or simply provide unacceptable distortion. It's unfortunate that while the regular TIG process has for decades delivered the best manual weld quality, that this process also requires the highest weld skills - delivers the lowest weld travel rates and result in high part heat which frequently has a negative influence on the alloy parts being welded. [] IN CONTRAST TO REGULAR TIG, the TIP TIG process always delivers the greater weld deposition rates enabling much faster weld speeds that will result in the lowest possible weld heat and lowest oxidation potential. The TIP TIG welds result in the smallest possible weld HAZ, the least weld distortion and the best possible metallurgical properties. [] IN CONTRAST TO REGULAR TIG, the TIP TIG process will always produce higher manual and automated weld quality and with TIP TIG you should always expect the lowest weld rework costs. [] IN CONTRAST TO REGULAR TIG, welding faster with TIG enables a dramatic reduction in weld labor and consumables costs. [] IN CONTRAST TO REGULAR TIG, the TIP TIG process reduces all position pipe weld skills and allows "manual" pipe welders to produce automated weld quality. [] IN CONTRAST TO ANY MANUAL WELD PROCESS TIP TIG HAS GREAT WELDER APPEAL. The TIP TIG process produces the cleanest welds which typically require no grinding or cleaning. TIP TIG welds are made with light weight torches and the welds should always generate with the least weld fumes. Best Manual Weld Practices and Weld Process Controls: To the chagrin of many weld QA managers and inspectors especially in the Power, Oil, Aerospace and Defense industries, manual TIG pipe - fabrication weld quality will be highly influenced by the welder' s inconsistent skills delivered by each welder. The bottom line for any QA department, when the weld shop utilizes the manual TIG process, the weld shop is using a process in which it's difficult to apply Uniform Best Weld Practices or Weld Process Controls. [] TIP TIG has changed the manual TIG process into a "Semi-Automatic" process like MIG. Please note that two of the most important influences on controlling metallurgical properties with alloy welds TIG welds is the weld speed that can be attained and the weld speed consistency and uniformity that can be achieved. The constant fed TIP TIG weld wire dictates the required manual weld speeds, enables higher speeds and brings a weld heat uniformity and consistency to the welds produced. [] TIP TIG does what the manual TIG welder is incapable of doing, the TIP TIG small weld wire diameter achieves "uniform melting" as the weld wire is consistently fed at a fixed rate into the "weld's arc sweet spot". [] TIP TIG increased weld energy and weld pool agitation dramatically changes the TIG weld pool dynamics and allows the use of small wire diameter fed at high wire feed rates. The TIP TIG weld has a larger fluid weld area which is very receptive to the rapid fed, small wire. Small wires, higher weld energy and welds with increased weld solidification dramatically reduce the common lack of fusion and porosity defects revealed by NDT. These TIP TIG benefits also reduce the concerns when welding sluggish alloys. [] TIP TIG allows the widest joules range and the lowest weld heat so you can be sure with any alloy of always attaining the best possible mechanical and corrosion properties. [] TIP TIG has eliminated the need to manually feed the weld wire or the need for a foot control. TIP TIG lets the operator control the torch with one or two hands and this process allows the welder to concentrate on what's going on in the TIG arc zone.

 

EVERYONE KNOWS THE WELD HEAT & OXIDATION
CONCERNS WHEN TIG OR PULSED MIG WELDING TITANIUM.

 

The following Titanium welds are not possible with either the manual Pulsed MIG or Regular TIG process.

 

 

TIP TIG WELDING GRADE 2 TITANIUM AT 24 inch/min
WITHOUT THE USE OF A GAS TRAILING SHIELD.

TIP TIG welding Grade 2 Titanium without the use of a Gas Trail Shield. While using the slow manual or automated regular TIG process, there is always concern about the oxidation effects when welding titanium and welding many other alloys. Regular manual or mechanized TIG welds on Titanium parts 3 - 6 mm will be carried at typical weld speeds in the 2 to 6 inch/min range. To protect the low speed, high heat TIG welds, from oxidation, trailing gas shields have always been a critical weld requirement. THIS TIP TIG TITANIUM WELD IS MADE AT AN APPROX. TRAVEL RATE OF 24 inch/min SO THE TITANIUM PART DOES NOT REACH A TEMPERATURE IN WHICH TITANIUM WELD OXIDATION IS A CONCERN. NOTE THE UNTOUCHED SILVER COLOR.

When some of the largest Oil and Titanium Fabricators in China saw the TIP TIG
process, they quickly came to TIP TIG USA become TIP TIG customers.

TIP TIG, HIGHEST QUALITY, SILVER COLOR TITANIUM WELDS WITHOUT THE USE OF A GAS TRAILING SHIELD. TIP TIG titanium welds like the ones above are made 200 - 400% faster than regular TIG and with no manual wire feed requirements, no foot control, less weld skills are required. With TIP TIG there is no weld spatter and always the lowest weld distortion. TIP TIG enables the lowest possible weld fumes, the lowest gas costs. In contrast to TIG with TIP TIG you will have lower wire costs and no wasted costly titanium wire ends. With any titanium welding applications, in contrast to regular TIG and pulsed MIG processes, TIP TIG will always produce the highest possible weld quality.

 

 

REF: ABOVE VIDEO WELDING TITANIUM. When welding titanium or any alloy highly sensitive to weld heat oxidation, you know that if X- Rays are required you will likely expect to find weld porosity. In contrast to regular TIG weld speeds on titanium welds which are typically 2 to 8 inch/min, when using the manual or automated TIP TIG process the titanium weld speeds will depending on the thickness typically be in the 10 to 45 inch/min range. As indicated in the above video, the higher TIP TIG weld speeds enable the TIP TIG titanium welds to produce much lower weld heat resulting in untouched, 100% silver welds without the use of a gas trailing shield. The above 3/16 (5mm) Grade 2 Titanium TIP TIG lap weld was made at approx. 24 inch/min. A TIP TIG manual 1/8 (3 mm) fillet weld would be at a weld travel rate of 25 to 40 inch/min. If your organization uses regular TIG on Titanium, you will be pleased to know that with TIP TIG that most manual or automated titanium welds will typically be done 200 to 400% faster. The TIP TIG welds will have superior weld quality than that attained with either the regular TIG or the Pulsed MIG process. With TIP TIG your weld rework costs are dramatically reduced, your weld gas costs should be reduced by at least 50% and your weld wire costs should be reduced 15 to 20%. You may be shocked to hear these claims, however remember all it takes is a 10 minute demo at our facility to prove them.

 

TIP TIG USA is the exclusive supplier of TIP TIG equipment
in North & South America and Australia.

TIP TIG USA sells and services unique, cost effective manual & automated pipe - fabrication weld & cladding equipment. Please note, It's no good calling your weld distributor about the TIP TIG process, they don't have it. For sales - quotes - parts or if you wish to send weld samples, phone Nick Corso, eastern time at 856 312 8164. E-Mail Nick at nick@tiptigusa.com. For TIP TIG and any weld application questions, phone Ed. Craig eastern time at 828 337 2695. E-Mail. Ed at ed@tiptigusa.com. We are looking for TIP TIG dealers in Canada - Brazil. EMail Tom at tom@tiptigusa.com.

Many companies will consider spending $100,000 to $250,000 for a TIG robot weld cell, not realizing that that for 10 to 20% of the costs, a manual, semi automatic TIP TIG welder could typically attain 100 - 400% more TIG weld production with superior weld quality and lower weld heat. Of course if you need to automate, you will still get the TIP TIG weld quality - productivity weld benefits. To provide the best possible robot or automated weld quality, click on TIP TIG Automation.

On welds like the above, in contrast to the robot using Hot Wire TIG, a manual TIP TIG welder will each hour typically produce 100 - 300% more weld and the weld will be superior quality. However if you want a robot to make code quality welds, the logical process to put on that robot is TIP TIG. CODE QUALITY WELDS? TIP TIG ENABLES MORE WELD PROCESS CONTROLS AND PROVIDES MORE WELD BENEFITS THAN ANY OTHER AVAILABLE MANUAL OR AUTOMATED WELD PROCESS.

 

 

Oil - Power - Defense - Space - Medical - Food Processing,

Optimum weld quality cannot be determined by weld inspection criteria that requests 10% NDT or by visual inspection. When "optimum weld quality" is discussed at this site, it means the ability of a process to meet the ASME Sect 1X requirements necessary to consistently attain 100% X-Ray welds.

Watch five manual TIG welders weld a pipe and you will see five different skill sets and view five different techniques in feeding the TIG wire into that weld. While the TIG process offers the best opportunity for the least weld defects, weld defects will occur and typically it's the manual, variable, idiosyncrasies involved in feeding the short wire lengths into the rapid freeze small weld pool that are the reasons for those TIG weld defects. When a foot control is used with a regular TIG weld each welder will be using variable weld current. When you combine the wire feed idiosyncrasies with the inconsistent weld current from the foot control its difficult to attain uniform weld quality and comply with pre-qualified weld procedures. The greater the required weld skills for a TIG application, the greater the potential for weld defects. MANUAL TIP TIG IS A "SEMI-AUTOMATIC" TIG PROCESS THAT TAKES THE TIG WIRE FEED OUT OF THE WELDER'S HANDS. TO OPERATE THE TIP TIG PROCESS, THE WELDER REQUIRES ONLY ONE HAND AND FOR IMPROVED TORCH CONTROL WHEN REQUIRED THE WELDER CAN USE TWO HANDS AS INDICATED BELOW. ALSO WITH TIP TIG THE WELDER DOES NOT NEED A FOOT CONTROL SO WITH EVERY TIP TIG WELD APPLICATION THE WELD CURRENT IS CONSTANT. TIP TIG ALWAYS PROVIDE SUPERIOR ALL POSITION TIG WELD QUALITY AND TIP TIG ENABLES UNIQUE WELD QUALITY CONTROLS FOR ALL MANUAL TIG WELDS. WHY WORRY ABOUT THE GLOBAL SHORTAGE OF SKILLED TIG PIPE WELDERS? There is a global shortage of good pipe welders and irrespective of what ever the weld process utilized. thanks to the common global government budget cut backs in skills training, that shortage will be around for at least the next decade. When an organization needs to hire or train TIG welders, remember with TIP TIG you will produce superior pipe weld quality than regular TIG and achieve those welds with much lower costs from welders who require less weld skills. MAINTAINING COMPLIANCE WITH WELD PROCEDURES IS EASIER WITH TIP TIG: [] Every TIP TIG welder working on pipe sees immediate improvements in their pipe weld quality. In contrast to manual TIG, the welder notes that the constant fed TIP TIG wire helps maintain consistent weld energy, promotes consistent side wall weld fusion and drives constant weld speeds. The TIP TIG pipe welder sees in a weld a quality and uniformity they never attained with regular TIG. Note. For those QA managers and weld engineers in charge of constructing power plants, oil platforms, nuclear submarines, LNG storage vessels or any code quality application. You are all aware that the weld travel rate is one of the most important weld variables, especially when attaining consistent weld fusion with the common sluggish alloy applications. With regular manual TIG there is one weld speed "slow" and the manual TIG weld speeds will always be inconsistent. With TIP TIG the weld speeds are regulated by the preset constant wire feed rates and those rates can be set at either low or high settings to suit any weld heat input requirements. [] In contrast to manual TIG, with TIP TIG you have Hot Wire Current which is added to the higher weld current that's generated from the increased TIP TIG weld deposition rates. Combine the higher TIP TIG current with the unique TIP TIG agitated weld pool and you will have no more concerns when welding sluggish alloys of any thickness and you will not need argon - Helium or Argon Hydrogen gas mixes. [] TIP TIG in contrast to any other manual weld process provides the lowest possible weld heat which is a key factor for multi-pass weld cleanliness. The low TIP TIG weld heat and inert argon enables the lowest weld oxidation (cleanest welds). The increased weld energy and weld agitation produces welds with the lowest weld pores and inclusions. Those weld shops that are wasting time and money with grinding and weld cleaning need to look at the cost effective solutions TIP TIG can provide.

 

 

Regular TIG versus TIP TIG Weld Feature Benefits:

WELD CONSIDERATIONS	REGULAR TIG	TIP TIG
Weld current per application.	TIG uses less current and larger weld wires. TIP produces a smaller fluid weld area with faster weld solidification.	TIP TIG allows the use of more suitable smaller wire diameters and higher wire feed rates that enable higher weld current. TIP TIG also provides hot wire current and an agitated weld pool. TIP TIG welds should provide superior weld fusion and the welds will contain less porosity.
Weld deposition rates per application.	TIG provides very low deposition rates creating high labor costs.	TIP TIG typically enable 100 to 300% more weld each hour dramatically reducing TIG labor - consumable costs.
Weld travel rates per application.	TIG typically provides the slowest weld travel rates.	TIP TIG typically enables 200 to 400% faster weld travel rates producing the lowest weld oxidation (cleanest welds) with a dramatic reduction in weld distortion potential.
Weld joules per application.	TIG weld joules are primarily influenced by the slow weld travel rates.	TIP TIG enables a wider weld current range than regular TIG making it more suited to specific applications. TIP TIG also provides much faster weld travel rates enabling the lowest possible weld joules.
Weld quality.	lower quality as a result of the inconsistent weld skills and inferior weld dynamics.	TIP TIG, always superior weld fusion - always less porosity - always cleaner welds, less concerns with sluggish alloys, less skills, consistent wire feed rates and consistent placement of weld wire into the arc sweet spot.
Weld metallurgy.	TIG cannot attain the weld and part metallurgical properties attained with TIP TIG.	TIP TIG provides higher weld quality and lower weld heat from the faster travel rates, this combination should result in superior weld or clad mechanicals - corrosion properties.
Weld applications.	TIG is restricted due to its low deposition rates, and weld current restrictions.	TIP TIG is practical on any steel or alloy steel application, any thickness and any weld position.
Weld skills.	TIG, high skills from feeding the weld wire and operating the foot control.	TIP TIG does not require the welder to feed a weld wire and TIP TIG does not use a foot control. These two factors dramatically reduce the required weld skills.
Weld fumes.	TIG slower weld speeds mean greater weld heat and higher weld fumes	TIP TIG lower weld heat from faster weld travel enables the lowest possible weld fumes.
Suitability for automation.	TIG without hot wire current and AVC controls is poorly suited to weld automation.	TIP TIG well suited to any weld automation.

TIP TIG manual welds should always be superior weld quality than any regular TIG -
Hot Wire TIG - CMT MIG - Pulsed MIG welds or welds made with Polysoude equipment.

TIP TIG, by the time you would set this part on a robot, the TIP TIG manual welds would be finished and the TIP TIG weld quality would be better than any automated regular or Hot Wire TIG weld, pulsed MIG or the CMT process. Remember this TIP TIG weld is being made 200 - 300% faster than a regular manual TIG weld.	TIP TIG. If welding parts for a nuclear power plant or for a defence contractor you will have two major concerns. [1] Meet the stringent weld code requirements without weld rework. [2] Meet the stringent dimensional requirements without concern for distortion. Note the untouched weld cleanliness (low oxidation is always an indication of low weld heat) and note the lack of weld fumes.

MIG IS EASY TO ADAPT TO AUTOMATION BECAUSE IT'S A SEMI-AUTOMATIC PROCESS.
THE semi-automatic TIP TIG process with it's superior weld quality - no spatter - lowest distortion -
no fume concerns and always cleaner welds. TIP TIG is also easily adapted to any weld automation.


WOULD YOU LIKE TO IMPROVE YOUR EXISTING AUTOMATED TIG PRODUCTIVITY?
JUST CHANGE YOUR TIG WELD EQUIPMENT TO THE TIP TIG PROCESS:

When we say TIP TIG will change the weld industry, take note of the influence of TIP TIG on weld automation. The above picture shows an automated, Jetline Seam TIG weld unit. This unit when making TIG welds on the gage stainless seams welds will typically make those welds in the travel range of 4 - 12 inch/min. Simply add a TIP TIG unit to that JetLine or similar automated TIG weld equipment and the average weld speeds on the same parts will be typically one to four hundred percent faster. With the TIP TIG process, no weld rework costs, no weld distortion, no weld cleaning. Also note that you could do many of these seam welds with a low cost Bug-O (carriage) or manually weld the parts with TIP TIG and still get outstanding weld results.

A GREAT WELD PROCESS SHOULD
PROVIDE GREAT WELD SOLUTIONS.

Welding growth comes from welding alloys? WITH EVERY ALLOY "EXCESS WELD HEAT" is a prime root cause of mechanical - corrosion issues. Of all available weld processes, TIP TIG always provides the lowest weld heat and the widest possible weld joules range.

 

PULSED MIG VERSUS TIP TIG:

WELD PROCESSES - WELD ENERGY AND POLARITY INFLUENCE ON YOUR WELDS. On many common, all position weld applications, the reverse polarity pulsed MIG and flux cored (FCAW processes will frequently provide insufficient weld energy for the weld mass (deposition rates) attained. With reverse polarity, the majority of the arc energy is focused at the weld wire tip. The concentrated energy in the MIG and FCAW weld arc plasma results in high energy at the weld's heat affected zone (HAZ), influencing both distortion and the part's mechanical properties. When welding all position welds with MIG and FCAW, and a macro weld evaluation is provided to examine the fusion, the fusion attained with optimum weld parameters will often be revealed to be marginal. Lack of weld fusion and unacceptable weld porosity is common with these two weld processes. The weld energy with manual Pulsed MIG and FCAW all position welds is also greatly influenced by wire stick out (WSO) variations which are normal with these processes. When manual welding groove welds on parts > 9mm you will find that small MIG and flux cored WSO extensions can readily decrease the weld energy in the 10 - 20% range. The reduced weld energy can decrease the weld fusion potential and increase the weld porosity potential. Wire stick out changes can also influence metallurgical changes and this is one of the reasons for inconsistent ferrite - austenite levels when welding duplex applications. When using Pulsed MIG on low to moderate current all position pipe welds, or on any welds made with sluggish alloys, the weld energy generated is often insufficient for the weld mass (deposition rate) delivered and for the weld speeds that are generated. In contrast to the lack of sufficient energy for that vertical up pulsed MIG weld, it's ironic that the concentrated, localized weld heat influenced by the MIG reverse polarity will frequently lead to excess weld heat in the parts, especially around the weld HAZ. REGULAR TIG. HIGH WELD HEAT AND EXCESS PART HEAT: In contrast to Pulsed MIG and Flux Cored, the regular TIG process provides a much higher temperature, more focused arc. The TIG process also provides much lower weld deposition rates, this is a combination which should always produce superior weld quality. The primary weld issue with TIG process is the high skills required and the slow weld speeds which often place excess weld heat into the parts. TIP TIG, HIGHEST WELD ENERGY AND LOWEST PART HEAT: In contrast to Regular TIG - Pulsed MIG and Flux Cored, the TIP TIG process provides the highest arc temperatures and highest weld energy which when combined with the agitated welds and moderate weld deposition rates should always provide superior weld fusion with the lowest weld pores and inclusions content. As TIP TIG provides much higher weld deposition rates than regular TIG, the TIP TIG process enables much faster TIG weld speeds. When you combine the increased TIP TIG weld speeds with the Electrode Negative weld heat dissipation benefits, you produce unique welds that will produce the lowest possible weld heat into any welded part. CHECK OUT THE TIP TIG PIPE SECTION TO VIEW THE LOWEST ATTAINABLE WELD KJi.

WITH TIP TIG, THE PRE-HEAT - INTERPASS - POST HEAT RULES MAY CHANGE.

In the last five decades, you could take any alloy weld application and to attain sound welds with acceptable base metal mechanical properties, you may have been been guided by standard weld preheat recommendations. These recommendations would have been based on the typical weld joules input achieved from the common manual TIG - SMAW - FCAW - SAW - MIG processes. WITH THE TIP TIG PROCESS, THE WELD RULES WILL CHANGE: In contrast to all other weld processes, when using TIP TIG, the weld heat into the base metals will be dramatically reduced. With TIP TIG you will have less concerns for welding heat sensitive alloys and you may want to consider using lower pre-heat weld temperatures, and also consider reducing the edge preps used.

 

Download our TIP TIG brochure.

Download our TIP TIG brochure.

 

TIP TIG, PERFECT WELDS ON ANOTHER DIFFICULT ALLOY CALLED INVAR.

Invar an alloy suited to very high temp applications. When welding you will note how sluggish the alloy is and how readily it's subject to oxidation. With pulsed MIG and regular TIG you should be concerned about the weld fusion and weld quality attained. On large parts like this 1/2 Invar, regular TIG would take for ever, and weld distortion, lack of fusion & excess oxidation would be major concerns.

Untouched after welding. Imagine the multi-pass weld quality that could be attained with TIP TIG and take a look at the small weld HAZ that results. THERE IS ONLY ONE PROCESS IN THE WORLD CAPABLE OF PRODUCING THIS TYPE OF WELD QUALITY WITH A DIFFICULT ALLOY SUCH AS INVAR, THAT WELD PROCESS IS TIP TIG.

Note" For those that think that's a crack in the center of the Invar weld (picture above right), it's not a crack its a "weld solidification line" When you produce an optimum quality weld, the last place to solidify in a fillet is the weld center and if the weld energy and weld cooling is uniform and rapid enough a line will often be evident in the weld center.

 

LOGICAL REASONS TO CONSIDER TIP TIG:

FROM THE PIPE WELDS IN A NUCLEAR POWER PLANT, TO THE WELDS IN AN OIL REFINEARY, NO OTHER MANUAL OR AUTOMATED PROCESS CAN CONSISTENTLY DELIVER THE WELD QUALITY ATTAINABLE BY TIP TIG. If you use regular TIG - Pulsed MIG or Flux Cored for manual code quality pipe welds, note that the superior & more consistent weld quality from TIP TIG will mean Less Weld Rework Costs. Extensive TIP TIG pipe data and videos in the pipe section. SUPERIOR PIPE WELD QUALITY: In contrast to the regular "manual TIG process", TIP TIG dramatically reduces the required weld arc start and stops. SUPERIOR PIPE WELD QUALITY: TIP TIG consistently directs the continuous fed weld wire into the weld arc sweet spot. This controlled weld wire action along with the use of a small diameter wires provides a weld consumable melting uniformity and weld quality consistency never experienced by a regular manual TIG welder. SUPERIOR PIPE WELD QUALITY: In contrast to Pulsed MIG and Flux Cored, the TIP TIG process provides automatic ramp up - ramp down weld current at the arc start and arc ends. These important weld controls along with the higher, focused TIP TIG weld energy and TIP TIG weld agitation always provides superior welds at any arc start - stops. SUPERIOR PIPE WELD QUALITY: With TIP TIG there are no Wire Stick Out change concerns: With manual pulsed MIG and Flux Cored, the welds can be influenced by small weld wire stick out variations during the weld. The wire stick out changes can dramatically effect the weld current (weld energy) delivered, influencing fusion and porosity weld defects and also influencing clad dilution or the weld and part mechanical properties. SUPERIOR PIPE WELD QUALITY: TIP TIG always Enables Cleaner Welds than any other weld process. Note the untouched manual, 5G pipe weld pass on left, note also the manual weld continuity - uniformity that looks like this manual pipe weld was carried out with costly weld automation. WHEN YOUR MANUAL TIP TIG PIPE WELD QUALITY IS SUPERIOR TO MOST AUTOMATED WELDS, IMAGINE WHAT YOU COULD ACHIEVE ONCE YOU USE OUR TIP TIG PIPE AUTOMATION EQUIPMENT. TIP TIG pipe welds are made at much faster weld speeds than regular manual TIG. The electrode negative benefits and lower heat from TIP TIG result is the lowest weld oxidation potential which produces the cleanest possible welds. Add the extra TIP TIG weld energy and weld agitation and you should expect the lowest possible pore and inclusion content. This benefit is especially important for multi-pass welds and any code welds subject to internal evaluation. SUPERIOR PIPE WELD QUALITY: In contrast to regular TIG or Pulsed MIG, the higher weld energy (increased TIG current capability) TIP TIG process combined with the unique agitated weld pool reduces pipe weld fusion concerns common with sluggish alloys. TIP TIG THE MOST VERSATILE ALL POSITION WELDING PROCESS. The TIP TIG process is without weld position or part thickness limitations as viewed with this untouched 1/4 (6mm) fillet. The TIP TIG process will produce the highest attainable weld quality on any metal, any thickness and in any weld position. TIP TIG & LOWER LABOUR - CONSUMABLE COSTS: TIP TIG will dramatically lower your TIG manual weld labor costs as TIP TIG typically provides 100 - 400% greater weld deposition rates and allows for a dramatic increase in arc on time. These weld benefits also dramatically decrease the argon gas costs. As the TIP TIG weld wire is attainable from the lower cost wire MIG spools, reels or drums, TIG wire costs should also be reduced. TIP TIG WELL SUITED TO ALL WELD AUTOMATION. The automated Hot / Cold Wire TIG welds are often made on parts that will require low to moderate current, (< 250 amps). These welds will frequently be considered "highly sensitive to small process variable changes". Automated Voltage Controls (AVC) with extremely tight tolerances are necessary for these welds. In contrast to the HOT Wire process, TIP TIG changes the weld pool dynamics and dramatically reduces the sensitivity of the weld to wire feed delivery. In many instance TIP TIG when used with weld automation will not require sophisticated, costly equipment like AVC. TIP TIG THE LOWEST POSSIBLE WELD FUMES: In contrast to the weld shop on the left using flux cored, when the weld shop uses TIP TIG the weld fumes produced will be the lowest possible from any conventional weld process. Exhaust equipment is typically not required for the majority of TIP TIG alloy welds even when welding with duplex, stainless or other high chrome weld wires. Please remember that when welding ferrous metals and alloy steels, both MIG and flux cored steel welds require "active gases such as CO2 or oxygen". TIP TIG does not require gas mixes it simply uses inert argon for all welds. TIP TIG TORCH ERGONOMICS: The TIP TIG water cooled torch is much lighter and easier to use than any MIG or flux cored gun. The torch can be as small or large as any available TIG torch.

WITH TIP TIG AND THE TWO SIDE ROOT WELD CAPABILITY,
THE QUESTION WILL BE, TO PURGE OR NOT TO PURGE?

While excellent purge products like these are fine for pipe alloy root weld applications that require a purge gas, the large purge dam as shown may not be required with TIP TIG. On many large applications TIP TIG can use a 2 Side Open Root Technique that does not require a purge gas.

TIP TIG welders below are using the 2 Side TIP TIG Root Technique without purge gas on the stainless vessel below. Also note the extremely low fume content from the two sided welders both inside and outside the vessel. if you want info on the TIP TIG two side weld E-mail Ed at ed@tiptigusa.com or nick@tiptigusa.com. Two Side TIP TIG Open Root technique enables first time open root weld quality with no purge, no ceramics, no grinding and no gouging.

On this application the average open vee groove root and fill
TIP TIG fill weld speeds is 12 - 20 inch/min. Note lack of fumes.

More Weld Benefits from the TIP TIG process: Photo on right. TIP TIG producing manual welds which are superior than the automated TIG - MIG welds typically made on heat exchange tube to plate. [] YOU WANT TO PRODUCE THE LOWEST WELD DISTORTION OR WELDS WITH THE LOWEST WELD STRESSES: In contrast to regular TIG, Flux Cored and Pulsed MIG, the TIP TIG process provides the lowest possible weld heat input and should dramatically reduce weld distortion, also the weld agitation has to reduce weld solidification stresses. [] YOU HAVE A CONCERN FOR WELD CRACKS: If the alloy weld consumables or base metal alloys are considered crack sensitive, that sensitivity always influenced by "heat" will be reduced or eliminated with TIP TIG, a process that puts less heat into a weld than any other process. [] YOU WANT TO ATTAIN THE BENEFITS FROM REDUCED GROOVE DIMENSIONS: As TIP TIG enables superior side wall weld fusion than the regular TIG or Pulsed MIG process, you can frequently reduce the conventional Vee - J groove pipe - plate edge preps, enabling a dramatic reduction in weld labor - consumable costs and also enabling the lowest possible weld heat for the application. [] YOU ARE CONCERNED WITH WELD FUSION - POROSITY THAT OCCURS WITH SLUGGISH ALLOYS: If you weld sluggish alloys like high duplex, inconel and stainless steels, you will have the least weld fusion and porosity concerns when you use the TIP TIG process. [] YOU WOULD LIKE TO REDUCE OR ELIMINATE WELD PREHEAT - INTERPASS - POSTHEAT TEMPERATURES: The weld temperature controls typically used when welding alloys with regular TIG, MIG or Flux Cored may be reduced or eliminated with TIP TIG as this process always provides lower weld heat. [] YOU WANT TO REDUCE WELD OXIDATION AND PROVIDE THE CLEANEST POSSIBLE WELDS: As TIP TIG welds provide the lowest possible weld heat input with inert argon, TIP TIG always provides welds with the least oxide reaction, providing the cleanest possible welds that will have the lowest weld pores and inclusions. [] YOUR APPLICATION REQUIRES THE BEST POSSIBLE METALLURGICAL PROPERTIES: When the highest weld quality is produced with the lowest weld heat, you have the potential to attain the best possible weld and part mechanical and corrosion properties, [] YOU HAVE 100% X-RAY REQUIREMENT AND WANT TO REDUCE LACK OF WELD FUSION DEFECTS: Thanks to the unique TIP TIG weld agitation combined with the highest possible TIG weld energy, no other manual weld process will provide the consistent fusion that can be attained by the TIP TIG process.

Manual TIP TIG on Heat Exchange welds.

 

MANUAL TIP TIG WELDS ARE ALWAYS SUPERIOR THAN ANY AUTOMATED MIG MODES, REGULAR TIG OR FLUX CORED WELDS: Examine the manual, stainless, untouched TIP TIG cooling tube welds above and in the video below. These manual welds made in the weld position as indicated in the photo. The welds were made by the welder shown below. Note the "untouched" weld cleanliness and very small HAZ. The manual TIP TIG welds created a uniform, consistent 360 degree fillet weld quality that could only be matched with a very costly, automated orbital welding unit.

MANUAL TIP TIG ON ALLOY 800
HEAT EXCHANGER WELDS:

Why would you purchase costly weld automation for this application when the manual TIP TIG weld requires approx. 90 seconds per tube and the TIP TIG manual weld will be superior to any automated weld. Examine the manual weld quality and lack of HAZ on the untouched welds. TIP TIG enables higher weld quality & lower distortion than manual - automated regular TIG, Flux Cored and Pulsed MIG welds.

 

To witness the extraordinary TIG weld quality and productivity improvements and weld controls provided by the TIP TIG process on any steels or alloys you wish to bring, we invite you to visit or contact us. E-Mail. Nick Corso nick@tiptigusa.com. Phone. Nick at 856 312 8164. For a discussion on your weld application, E-Mail Ed Craig at ed@tiptigusa.com or call Ed at 828 337 2695.

We are looking for TIP TIG dealers.

We are looking in Texas - Brazil and Canada
for technical companies that want to sell TIP TIG.
Contact Tom O'Malley. tom@tiptigusa.com.

Interested in Robots - Automated TIP TIG Applications?
Visit TIP TIG weld automation.



INDUSTRIES IN WHICH TIP TIG WILL PROVIDE TREMENDOUS
WELD QUALITY AND PRODUCTIVITY BENEFITS

A few of the companies who purchased the TIP TIG process or attended the TIP TIG work shops. EXON - HALIBURTON - AREVA - WESTINGHOUSE - BECHTEL - FLUOR - ROLLS ROYCE - WELDING SERVICES / AQUILEX - NORTHROP GRUMMAN - SIEMENS - NOOTER - TI-FAB - DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE - TRIUMPH FABRICATIONS - ENERFAB - DIAMOND POWER - BODY COTE - SPACEX - KELLY CONSTRUCTION - THOMPSON FAB.

THE TIP TIG PROCESS & INVESTMENT CAST WELD REPAIRS.

TIP TIG, THE WELD PROCESS SOLUTION FOR INVESTMENT CASTINGS WELD REPAIRS: When you have to provide cast weld repairs on an engine used in a USA fighter plane you select TIP TIG. The TIP TIG process will provide welds with the lowest weld heat enabling minimum influence on the casting's metallurgical properties. TIP TIG will produce welds that can attain consistent fusion with the lowest dilution. TIP TIG will produce welds that will produce the least weld distortion. TIP TIG will produce welds with no slag, no spatter and the least porosity.

The weld benefits that apply with TIP TIG and Investment Castings, applies to all alloy welds: None of the following weld manual weld processes, regular TIG, Pulsed MIG or Flux Cored can provide the manual alloy weld repair quality that the TIP TIG process can deliver. TIP TIG CAST OR ANY ALLOY WELDS. The manual increased TIP TIG weld deposition rates enable much faster TIG weld travel rates that will result in the lowest possible weld heat input for any + heat sensitive cast components. The manual TIP TIG process provides uniform, constant weld wire delivery to the arc sweet spot, which combines with the agitated weld pool improves optimum weld fusion while enabling the release of internal stresses and pore defects. In contrast to any other weld process used on cast repairs, TIP TIG will always produce [] the lowest possible weld heat input, [] the lowest weld stresses, [] the lowest weld fumes, [] and no grinding required. A 10 minute demo at our New Jersey facility or with our Houston distributor is all you will need to see that in contrast to any other process, the TIP TIG process should always deliver the best weld results for your costly, investment cast weld repairs.

Complex Investment Cast Alloys and TIP TIG Weld Repairs.

No matter what the Cast Alloy to be welded is, no other manual process will provide the weld repair quality attainable from TIP TIG.

BRING YOUR INVESTMENT CAST COMPONENTS OR SEND A SAMPLE TO OUR RUNNEMEDE FACILITY IN NEW JERSY AND IN 15 MINUTES WE WILL SHOW YOU A WELD QUALITY - WELD PRODUCTIVITY - LOW HEAT COMBINATION YOU SIMPLY HAVE NEVER BEEN ABLE TO ATTAIN WITH YOUR WELD PROCESS.

Regular Manual TIG was considered not practical on large fabrications
that required optimum weld quality, that's not the case with TIP TIG.

IN CONTRAST TO REGULAR TIG, THE TIP TIG PROCESS IS SUITED TO LARGE WELD FABRICATIONS LIKE THIS SHIP'S DUPLEX CONTAINER. The duplex container (top section shown) is 30 foot (7.5 m) diameter with a 5/8 (16 mm) wall thickness. DUPLEX & TIP TIG. A prime benefit that should be of interest to any weld inspector or QA manager, the "semi-automatic" TIP TIG wire feed that's consistently fed to the optimum TIG arc position enables manual TIP TIG welders to provide good all position weld deposition rates and excellent weld conformance to the key essential weld variables generated during any weld qualification procedure. No spatter, no fumes, no weld cleaning and always there should be no weld rework. DUPLEX & FLUX CORED. The duplex container on the left was going to be welded with the Flux Cored process. With this fabrication, the duplex, all position, gas shielded, flux cored wires created lack of fusion, trapped slag, excess porosity unacceptable spatter, unacceptable weld fumes, the bottom line is flux cored led to high weld clean up and high weld rework costs. DUPLEX & PULSED MIG. They also considered Pulsed MIG for the all position duplex container welds. The duplex sluggish alloys created lack of weld fusion, porosity, distortion and weld fume concerns (same pulsed MIG weld issues I wrote about in my Management - Engineers Guide to MIG book written 14 years ago) . THE COMPANY TRIED TIP TIG AND IT IMMEDIATELY RESOLVED THEIR WELD QUALITY - PRODUCTIVITY AND FUME ISSUES. The weld solution for the company welding the duplex and stainless containers was the TIP TIG process. TIP TIG , has no concerns with sluggish duplex alloys. TIP TIG always provides the least amount of weld fumes. The agitated, high energy, TIP TIG duplex welds provided superior weld fusion and welds with the lowest weld pore content. With TIP TIG there is no spatter, no grinding, no cleaning and take a look at the absence of weld smoke with the above TIP TIG welder. The TIP TIG all position welds were carried out at similar deposition rates to the Pulsed MIG welds. THE COMPANY USING TIP TIG IN THE ABOVE PHOTO IS ONE OF EUROPE'S LARGEST FABRICATORS OF DUPLEX - STAINLESS CONTAINERS. AFTER PURCHASING MORE THAN 25 TIP TIG UNITS, THIS COMPANY NO LONGER USES EITHER THE PULSED MIG OR FLUX CORED PROCESS.

Superior Quality from Less Skills.

Note: TIP TIG welders do not require a foot control, and If the TIP TIG welders desire, they can improve the weld control with the use of two hands on the torch.

 

 

CONTROLLING IMPACTS, FERRITE, AUSTENITE OR CORROSION CONTENT FOR ALLOYS, DUPLEX OR STAINLESS WELDS - CLADD APPLICATIONS, VISIT THE TIP TIG PIPE SECTION AND FIND OUT WHY TIP TIG ENABLES THE GREATEST CONTROL OF ANY MANUAL OR AUTOMATED WELD.

MORE TIP TIG WELD BENEFITS IN CONTRAST TO REGULAR TIG:

FINALLY A PROCESS THAT ENABLES A DRAMATIC REDUCTION POTENTIAL FOR YOUR WELD LABOR AND WELD CONSUMABLE COSTS: The higher TIP TIG weld deposition rates result in much faster manual and automated TIG weld speeds. While average manual TIG weld travel rates are typically 1 to 8 inch/min, with TIP TIG, typical the average manual weld travel rates are 12 to 48 inch/min. The increased TIP TIG weld deposition dramatically reduce both manual and automated TIG weld labor costs. When you weld faster with the TIP TIG process you can achieve a substantial reduction in the weld gas used. With TIP TIG, the weld wire costs are also educed with no wasted weld wire ends and weld wires which is cheaper when purchased as MIG spools, reels or drums. PROVIDE CONSISTENT, UNIFORM, MANUAL & AUTOMATED WELD QUALITY: The TIP TIG high energy arc from the increased weld current capability, added to the unique patented agitated weld pool that slows down the weld solidification enables a greater amount of pore defects to rise out of the weld. The TIP TIG weld agitation also reduces weld stresses and improves weld fusion and reduces the concerns with sluggish alloys like duplex, inconels and stainless alloys. With TIP TIG you also have the benefits from the faster weld travel rates that lower weld heat which reduces part distortion. The increased weld speeds with electrode negative provide the lowest possible weld heat input and the lowest weld oxidation potential. Lower oxidation potential is important for cleaning those thin gage stainless welds and for cleaner weld passes with multi-pass welds. The low weld heat input enables superior weld - mechanical properties and if required less dilution for improved corrosion properties with clad welds. The unique, TIP TIG manual weld wire delivery consistently delivers the wire to the optimum arc sweet spot, this feat is impossible with regular manual TIG. Combine this with the constant TIP TIG wire feed which minimizes the manual arc starts / stops required per weld joint, (common regular TIG weld defect locations) and you have a consistent, uniform weld quality that can never be attained by regular manual TIG welder.

No matter how complex the alloys welded, when you use the TIP TIG weld
process there will always be less potential for weld quality issues,
weld metallurgical issues and distortion concerns.




TIP TIG APPLICATIONS. DEFENCE - MEDICAL - ELECTRONIC INDUSTRIES

SPACE - AIRCRAFT - POWER PLANT - OIL - GAS.

View the manual - automated TIP TIG sections to view
videos welding special alloys like Titanium, Hastelloy and Duplex.

CONCERNED ABOUT CRACKS - MECHANICALS OR CORROSION PROPERTIES? Providing the lowest possible weld heat and lowest weld dilution if required are two key weld benefits to reduce weld crack sensitivity: With the TIP TIG process you will always attain the lowest possible weld heat input and if required the widest possible weld joules range and the lowest possible weld dilution. TIP TIG has the potential with all alloys to produce superior weld and base metal mechanical and corrosion properties. It's nice to know that while you are providing weld solutions to the world's most complex alloys, in contrast to regular TIG, the TIP TIG weld costs will typically be in the range of 100 to 500%. HOW IMPORTANT IS IT TO YOUR ORGANIZATION TO WORK WITH A PROCESS THAT REQUIRES LESS ALL POSITION WELD SKILLS, PRODUCES THE HIGHEST WELD QUALITY REQUIRES MUCH LESS WELD TIME AND PROVIDES MORE WELD PRODUCTIVITY? AUSTRALIAN TIG WELDERS EARNING MORE THAN THE PRESIDENT OF THE USA. OCT 11. 2010 The "Australian" news paper reports that Australian offshore oil rig workers and welders received a 40% pay increase this year. Many TIG welders will be earning up to $2000 a day on Exxon Mobil / BHP Billiton Rig Installation projects and achieving similar pay on the Apaches's Reindeer Project in Western Australia. Note from Ed. The greatest portion of the welders pay comes from very generous benefits and allowances won by union contracts. The reality is these workers will typically make a very nice $100.000 to $250.000 annually. (Note: At this time Aus dollar is par or higher than the USA dollar) Update May 2011: Take note of the latest union agreement that has really got project executives concerned. It's a new deal for welders working in North West Australia. The welders work from a barge on Barrow Island (Australia Gorgon Project). Working 10 hour days, two weeks on, one week off, the welders will fly in fly out of Perth. They get free flights, free accommodation, free food and the company even washes their gear. The welders will receive approx $500,000.00 US for two thirds of a years work. Note: Few in this part of Australia who has an exceptional skills or certification (e.g. CWI, TIG welder, Rigger etc) will work for less than a thousand a day. Weld management needs to be aware that in contrast to the Stick - Pulsed MIG - Flux Cored and - Regular TIG processes on pipe welds, TIP TIG requires less weld skills and is easier to use. TIP TIG will always deliver superior weld quality and metallurgical properties than regular TIG and in that hot Ausy sun or any uncomfortable welding enviroment, the TIP TIG welders will complete the pipe or fabrication in a third of the time with a third of the sweat. Half a million a year salary for welders, it's a wacko world mate, but god bless the Ozy management who now have agreed to pay welders more money this year than what the president of the United States will earn. TIP TIG P91: MANAGERS TAKE NOTE. TIP TIG WILL LOWER YOUR TIG MANUAL & AUTO TIG PIPE WELD COSTS IN THE RANGE OF 50 TO 400%. TIP TIG is the only manual - automated, all position process capable of consistently producing optimum manual weld quality achieving welds that require the lowest possible weld rework. TIP TIG achieves this while providing moderate all position weld deposition rates from the root to the fill passes. With the TIP TIG process, the manual welder uses Fixed Wire Feed Rates so the resulting weld deposition rates are easy to figure. In the pipe section (link at bottom of this page) there is a regular TIG pipe weld versus TIP TIG pipe weld which provides a real world labor cost analysis. In contrast to regular TIG and Stick welds, with TIP TIG the manual pipe fill weld deposition is increased typically in the range of 100 to 400%. The TIP TIG increased manual weld production is attained without extra labor effort and the TIP TIG process would also provide superior pipe root / fill pass weld quality.

 

 

 

Optimum weld quality cannot be determined by weld inspection criteria that requests 10% NDT or by visual inspection. When "optimum weld quality" is discussed at this site, it means the ability of a process to meet the ASME Sect 1X requirements necessary to consistently attain 100% X-Ray welds.

 

TIP TIG. ALL POSITION MIG DEPOSITION RATES, NO SPATTER, NO SMOKE, AND NO REWORK.

A SUMMARY OF TIP TIG AND REGULAR TIG "ALL POSITION WELD DEPOSITION RATES:. How important is the following to a shop welding all position, code quality, pipe, plate or vessel applications? When welding 5G manual pipe fill pass welds, the regular manual TIG process used for the vertical up welds with a typical arc on time of 20 minutes per/hr will deliver approx. 0.3 lb/hr In contrast to regular TIG, for the pipe fill passes with TIP TIG you will typically increase the TIG pipe fill pass weld deposition rates by 200 to 400 %. A great bonus for weld shops is with TIP TIG you have the ideal process for both the root and fill passes, no STT, no RMD, no Pulsed MIG, no Flux Cored, no weld rework, minimum weld cleaning and no fumes.

 

FOR AN INDUSTRY DEDICATED TO CONSISTENT WELD QUALITY

 

For the power industry TIP TIG is the only "manual process in which effective weld process controls" can be enabled. With automated all position TIG welds, TIP TIG will produce superior weld quality and higher weld productivity than the automated Hot Wire TIG process

 

BELOW, ADD THE SEMI-AUTOMATIC TIP TIG PROCESS TO A LOW COST ROTARY POSITIONER OR A MECHANIZED CARRIAGE AND YOU HAVE A FULLY AUTOMATED WELD PROCES THAT WILL DELIVER A WELD QUALITY THAT IS NOT ATTAINABLE FROM ANY OTHER CONVENTIONAL MANUAL OR AUTOMATED WELD PROCESS.

TIP TIG Multi pass Oil Industry Application.

YOU CAN TRY REGULAR TIG, PULSED MIG AND FLUX CORED, HOWEVER TIP TIG
WILL ALWAYS PRODUCES SUPERIOR WELD QUALITY ON NICKEL ALLOYS.