Section 1. When the highest weld quality is required, the regular GTAW (TIG) process has for decades been the process of choice. It's unfortunate for the weld industry that TIG has required the highest welder skills, produced the lowest deposition rates that result in the lowest weld speeds and too often produce welds with excess heat and always results in welds that produce the highest weld labor costs. Welcome to the evolution of the TIG process, it's called TiP TiG.
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The patent pending TiP TiG process.
The most important part of the TiP TiG invention is the wire feeder. With the TIP TIG process, the constant fed weld wire is superimposed by a secondary high-speed oscillation which is generated by the patented, four-roll, mechanized drive plate. The wire feed mechanical action creates a vibration on the weld wire. The vibration passes through the weld wire into the molten TIG pool agitating the pool and slowing the weld solidification.
TiP TiG changes the Weld Dynamics:
Hot Wire (HW) current is used to preheat the weld wire. The HW current pre-heats and softens the weld wire increasing the wire receptivity to the weld pool and adds some energy to the weld. The combined attributes of the TiP TiG weld agitation and HW current create unique TIG weld dynamics which slows the TIG weld solidification and enlarges both the TIG plasma and the fluid TIG weld area. As the weld is agitated and the weld solidification time is increased you can add more wire with more current
The dynamics of TiP TiG are the same dynamics as why In the winter the pond freezes before the stream?
Video 1. Don't try this single pass, 7 mm, Incoloy weld with your TIG process.
With minimal weld benefits attained from weld process changes in the last three decades, what does a change in the TIG weld dynamics mean for a weld shop? For the 260 amp, high weld heat, single pass, 5/16, (8 mm) inconel fillet weld in the video, take note of the lack of oxidation (gold color weld) and the small weld HAZ, (lowest distortion and best metallurgical properties) these are features that result from a weld process that produces the lowest possible weld heat. If you are concerned about chrome - managanese or any alloy weld fumes, take a look at this TiP TiP weld and compare the weld fumes produced with your MIG and flux cored welds.
TiP TiG Weld Deposition: The unique TiP TiG weld pool enables small diameter wires to be used, (wire sizes better suited to the weld current used) and more weld wire to be fed into the weld pool. TiP TiG typically enables a 100 to 300% increase in TIG deposition rates. The increased TIP TIG wire feed rates enable much faster weld travel rates which combined with EN polarity dramatically lower the weld joules for every weld application. The increased TiP TiG wire also enables more TIG weld current to be utilized providing more weld energy. The TiP TiG weld pool changes enables a unique manual and automated weld process combination of the highest possible weld energy with the lowest possible weld heat, The TiP TiG process attributes produce numerous manual and automated weld quality and productivity benefits.
These are the primary equipment components in the TiP TiG process. It may look complex, yet with four weld settings you could construct a nuclear plant with the highest possible weld quality - productivity.
Single pass 309, 7 mm, TiP TiG fillet. Note the weld profile, the weld continuity, uniformity, surface, edges, and untouched weld cleanliness.
When a manual weld cannot be improved, you have selected the best weld process.
The many TiP TiG weld benefits should change a weld shops approach to TIG weld applications:
a.The superior agitated, higher energy TiP TiG weld fusion enables the weld shop to dramatically reduce weld edge prep dimensions. Instead of the traditional 60 - 75 degrees included Vee angles, with TiP TiG, depending on wall thickness you can use Vee included angles in the range of 40 - 55 degrees.
WITH TiP TiG BEVEL REDUCTIONS AND PROVIDING WELDS >200% FASTER THAN TIG WELDS, YOU CAN TYPICALLY EXPECT 200 T0 400%. REDUCTION IN TIG WELD COSTS
b. When the alloy content is substantial the welds are typically sluggish and weld fusion is often a concern for welds subject to NDT. The higher energy TiP TiG welds with slower weld solidification enable superior weld fusion with all alloys and carbon steels..
c. Faster TiP TIG weld speeds combined with inert argon and EN polarity provide welds with the lowest weld heat.and therefore the lowest weld oxidation potential, (cleanest possible welds). TiP TiG multipass welds will have the lowest weld pore and inclusion content. Producing the lowest possible weld heat enables lower weld pre-heats, less waiting or concern for interpass temperatures, less concerns for weld distortion, the lowest weld stresses and alloy welds that are crack sensitive will be less crack sensitive. Note: Low oxide potential with stainless also enables increased ferrite content which reduces weld crack potential.
THERE ARE ONLY TWO IMPORTANT WELD REQUIREMENTS NECESSARY FOR THE MAJORITY OF THE WORLD'S ALLOYS. PRODUCE THE HIGHEST WELD QUALITY WITH THE LOWEST WELD HEAT.
d. Without using special automated TIG "arc length control (AVC) equipment" which is normal with automated Hot - Cold Wire TIG welds, the TiP TiG process is suited to all automated applications including robots.
e. The TiP TiG process replaces multi-process requirements that are common with pipe root to fill passes.
f. TiP TiG can weld most pipes without an open root and weld thin wall < 6 mm pipes without edge preps or roots in a single pass.
g. In contrast to TIG, the TiP TiG process is suited to all weld position applications from gage to any thickness.
h. With TiP TiG no grinding wheels required and no other weld process will provide less weld fumes.
Video 2. As this heat exchange tube weld indicates, the global shortage of skilled TIG welders becomes less relevant when a process is introduced that improves weld quality and requires less skills.
This is a first time TiP TiG welder using TiP TiP on a complex heat exchanger tube to plate application. The manual welds are being made with better quality and 60% faster than the costly automated tube weld equipment typically used for these applications.
Video 3. We did not need a purge gas for these stainless open root welds.
When you get that new Tip TiG unit in your facility, remember this process enables "change" and therefore with TiP TiG you have the opportunity to change welding practices that have been applied to the TIG process for more than 50 years.
The following are few examples of how weld practices can change with a new process that consistently provides the highest manual - automated weld quality with the the lowest possible weld heat.
1. If you using standard pipe or plate bevels that have included vee groove angles between 60 - 75 degrees, with TiP TiG try 45 to 55 degrees typically enabling a 15 - 25 % reduction in filler metal.
2. If you use pre-heat, TiP TiG may eliminate or reduce the preheat, the same with post heat.
3. Stress relief? you may no longer require it.
4. Welding <6 mm pipe or plate parts and require full penetration welds. Instead of a bevel and root gap, with TiP TiG try a closed square edge and go for full penetration single pass, something you cant do with MIG.
5. If you weld roots with gaps, try the root welds "without gaps" with a feather edge up to a 0.060 land.
6. If you weld thin wall pipe such as sch 10, with TiP TiG you can 5G weld the pipe without edge preps or a gap.
7. If you are considering purchasing fume removal equipment, with TiP TiG you should not need it for most applications.
8. If you have been concerned about distortion, this process will reduce those concerns.
9. If you use a trailing gas shield such as with titanium welds, try TiP TiG without that shield.
10. If you use more than one weld process on code quality welds, you may now use one.
11. If you use different gas mixes, with TiP TiG you only need one gas for any alloy and that gas is argon.
Difficult welds highlight a weld process capability:
The tube to plate welds shown are typically done by highly skilled slow manual TIG welds or with very costly weld automated equipment. The 360 degree tube fillet welds were approx. 6mm and these TIG welds used to be done with two weld passes. The heat exchange company changed to manual TiP TiG welds. Production weld time was decreased by more than half and TiP TiG could produce the weld size required with a single weld pass. The TiP TiG process also improved the weld quality and reduced distortion. If you are considering costly automated weld equipment, you may first want to try the manual TiP TiG process as it will require less skills than you might think and it will also meet any weld quality - productivity expectations. If you want weld automation, take a look at TiP TiG's low cost automated equipment. Extensive TiP TiG manual data is in this section.
Video 4. TiP TiG heat exchange tubes to plate welds.
Lets take a look at TiP TiG and a Hastelloy 276 -31 mmShaft to a Flange weld. The weld on this side of the flange face has to fill in the flange groove, (future flange wear area). And on the other side of the flange, a 6 mm fillet on will join the shaft to flange.
TiP TiG, please note below "untouched single pass Hastelloy 276 groove flange fill pass. The TiP TiG weld time was under 30 secs. Then we turn the flange over to provide a fillet to weld to join the rear side shaft to the flange.
This side of the flange required a Hastelloy 276 shaft to flange fillet weld. Note again the silver color and small HAZ rom this untouched, single pass, TiP TiG fillet. As TiP TiG makes these welds four times faster than regular TIG, this TiP TiG weld cycle time was approx. 20 sec.
Note; TiP TiG always puts in much less weld heat than pulsed MIG, and approx. 30% of the weld heat of the regular TIG process. With TiP TiG, in contrast to TiG less weld skills are required and the combined weld cost labor - consumable costs were reduced by approx 80%. Note; regular TIG would also use twice as many weld passes. So with any alloy weld application, you know the benefits that will be attained from a process that consistently deliver the highest possible weld quality, the lowest possible weld heat, the least possible weld cleaning and lowest weld fumes. Every weld shop benefits when an application requires less weld skills. And every alloy part benefits from the lowest possible weld distortion and the best possible weld metallurgical properties. Your organization now has another weld process choice, it's called TiP TiG. You can email Ed Craig or Tom O'Malley anytime you have TiP TiG weld application questions, firstname.lastname@example.org - email@example.com. You may wish to send us weld samples in which we will weld and video, if so please email firstname.lastname@example.org. If interested in MIG or flux cored process controls visit my other web site at www.weldreality.com
Section 2. With manual TIG or MIG gauge welds, the weld surface quality, (smooth or irregular) lack of weld continuity - uniformity, distortion and oxidation (cleaning) that typically may require costly grinding and passivation are primary weld cost concerns. With MIG on gauge welds, you typically also may get over sized welds with convex irregular weld surfaces, poor weld tie ins and spatter issues. One way to demonstrate the extraordinary high weld quality and low weld heat benefits with TiP TiG, is to weld the ultra heat sensitive, titanium alloys without using a gas trail shield, or manually weld 14 gauge stainless at a weld travel rate of 48 inch/min as indicated below.
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Common TIG and MIG weld issues with thin gauge alloys that are less than 1/8 (< 3 mm).
Please review the following information and videos and compare the TiP TiG weld results with the weld quality, cleanliness and productivity attained in your organization.
REGULAR TIG GAUGE WELDS: When regular TIG welding gauge parts, the weld shop is often aware of the lack of TIG weld continuity and uniformity. The TIG weld quality is also influenced by the welders skills or the excess weld starts - stops. The very slow TIG weld speeds will often result in frustrating distortion and high weld oxidation that may require aggressive, costly weld cleaning practices. The extremely low weld speeds from the TIG process has be frustrating for managers who have a hard time finding skilled TIG welders and have applications that require a large amounts of weld.
MIG GAUGE WELDS: As most of you are aware, the majority of MIG welds will be over size with irregular , convex surfaces and spatter which in the processing industry means a good portion of the costly stainless welds will be ground to dust particles. Put the weld on then grind it off, that's a great way to add to the weld costs and also add unnecessary stainless particles in the weld shop atmosphere.
Video 1. TiP TiG 14 gauge Stainless. Regular TIG travel rates 5 to 10 inch/min. This TiP TiG 14 gauge weld travel rate is approx. 48 inch/min.
TiP TiG 14 gauge stainless weld. The weld shop wanted to produce the lowest possible weld distortion, increase the gauge weld productivity, cut back on weld grinding and passivation and of course achieve the lowest possible stainless weld fumes.
If you have a concern about finding skilled TIG welders and the high weld labor costs associated with TIG, take note: The 14 gauge weld in the video would typically be made on steels and alloy gauge parts 0.070 to 1/8, (1.8 - 3 mm). That fillet weld length in the video is approx. 12 inch (30 cm) long. Regular TIG weld travel rates on parts like this would be in the range of 5 to10 inch/min. In contrast, the TiP TiG weld speeds on this gauge stainless part was 48 inch/min.
EVERY GLOBAL WELD SHOP BENEFITS WHEN THE TIG WELD PROCESS SKILL REQUIREMENTS ARE REDUCED, WELD QUALITY IS IMPROVED AND WELD SPEEDS ARE INCREASED:
REDUCE WELD SKILLS: With TiP TiG, the welder does not have to feed a weld wire or operate a foot control which dramatically reduces the TIG skills. As you can see in the videos, the TiP TiG welder can focus strictly on the weld and use one or two hands to guide the torch in which the weld wire is consistently fed into the optimum arc position directly under the tungsten tip. With all manual TiP TiG welds, you should note the weld continuity and uniformity (like automated welds) that comes from the constant fed smaller weld wires. Also note from 14 gauge to a 7 mm single pass fillet, the smooth weld surfaces which are ideal for the food processing industry. With TiP TiG producing the lowest possible weld heat you should attain the smallest possible weld HAZ, the lowest possible distortion, no spatter and always that unusual, untouched weld cleanliness. Also note on the stainless gauge applications, while we are welding at MIG weld speeds we have no visable Hexavalent Chrome fumes and no weld spatter.
The highest weld quality and lowest weld distortion is important weld requirement on Nuclear Glove Boxes: TiP TiG enables larger single pass TIG welds, reduced TIG skills. increased weld quality and productivity with the lowest possible weld heat.
Video 2. TiP TiG Nuclear Glove Box. TiP TiG stainless and alloy fabrications, no distortion, cleanliness or weld fumes.
As with many nuclear components, this glove box required finished weld dimensional tolerances that are typically less than + - 0.010.
When it comes to weld quality, nuclear plants who live in the world of ASME code quality welds and stringent NDT requirements will often reject the use of the pulsed MIG and flux cored process. The nuclear glove box shown in the video had to be welded with TIG. With stainless or alloy weld fabrications in which extensive TIG welds are required, and the fillet weld sizes are typically in the 4 - 7 mm range, the TIG weld heat will be extensive and dimensional tolerances will always be an issue. One company making these products had to resort to using a large brake press to straighten some of the plate parts after a few welds were made. Another company making similar parts thought the solution was to use a robot to weld the parts. The 2012 robot provided no weld - heat benefits and at the end of the day had more down time than up time. Both companies making the nuclear glove boxes switched to the manual TiP TiG process and distortion was no longer an issue, TIG weld productivity was increased by approx. 200% and weld rework was typically zero
Note: Manual gage weld benefits are attained from the TIP TIG process when the fillet – butt welds are on parts > 0.050. Thinner parts may be manual and automated welded if the welds are lap welds or fixtures or backing is provided which acts as weld heat sink. We have used TiP TiG to weld 1 mm "lap" welds with automated TiP TiG equipment.
The ability of a weld process can be be judged in the weld results attained with complex alloys, and there is no alloy more complex than titanium.
Video 3. TiP TiG Simplifies Titanium Applications.
When welding any alloys, and especially welding titanium with the manual TIG or the automated Hot Wire TIG process, there is always concern about the weld oxidation. Weld shops evaluate the finished titanium weld quality by the untouched color of the completed weld. A silver color with an untouched titanium weld is the first choice.
Regular manual TIG welds on Titanium parts >3 mm are carried out at typical TIG weld speeds in the 2 to 5 inch/min range. The slow TIG weld speeds will create high temperatures and the solidified weld that trails the gas cup may be at temperatures that exceeds 700F. Once above this temperature the titanium, welds can result in oxidation reactions with the atmosphere.Those reactions will ruin the titanium properties creating costly scrap.
To protect the titanium welds, for decades welders have had to use extra large shielding nozzles and a cumbersome, argon trailing shield attached to their TIG or MIG torches and to the back side of the welds. With single pass, titanium TiP TiG welds made on parts over 4 mm, the weld heat measured within 3 mm of a fillet weld edge immediately at the weld completion is typically in the range of 300 to 380F. This temperature range is too low for weld oxidation to occur with any alloys.
When you can produce the highest weld quality with the lowest weld heat with any alloy welds, you not only produce the cleanest welds with the lowest weld pore content, you eliminate weld cracks, weld distortion, weld stress issues, and you should enable the highest possible weld - clad metallurgical properties.
Heat Exchange Tube Welds
Video 4. TiP TiG makes a complex heat exchange welds look simple.
1/4 tube, was welded to 1.75 inch plate. Procedure used to required two weld layers and was welded by automated TIG equipment.
View the middle tube below. Welded in the position shown, this manual tube weld was made by a first time user of the TiP TiG process. The TiP TiG weld was made on a 3/4 stainless tube 0.048 wall welded to a 1.75 inch stainless plate. With TiP TiG the TIG weld skills were dramatically reduced as the welder in this short cycle weld did not have to feed a wire or operate a current foot control.
If you look closely in the lower picture at the left welds (cut in half) these are regular TIG welds. The TIG welds have a more sluggish appearance and freeze lines are evident. Also because of the low deposition and the low weld heat with regular TIG, two weld layers were used.
Small. round and thin is always difficult weld combination to attain with manual welds. TiP TiG manual 3/4 tube 0.048 wall.
Untouched manual TiP TiG weld, compare with any automated tube to plate system.
The 3/4 completed tube welds are usually welded in the position shown, The welds in the video - photo were made by a first time TiP TiG welder.There was only one weld layer required to meet the weld specification (it took two layers with regular TIG) The tube to plate weld complexity is increased when the tubes to be welded are very thin (0.048) and small diameter and the plate they are welded to is very thick (1.75 inch). On many heat exchange welds, With manual The TiP TiG manual welds were better quality than the automated welds made by the Heat Exchange company, The weld fluidity - continuity - uniformity was improved and the weld production was increased by approx. 50%.
The degree of weld difficulty is increased with tube to plate welds when the tubes or pipes extend outside the plate as indicated below. With these welds you are welding a 360 degree fillet and the all position skill requirements are greater than the butt welds shown abTove. These single pass, manual 6 mm TiP TiG fillet welds were made in the weld position shown.
Video 5. A frequent question with TiP TiG, is why bother with automated TIG equipment?
When manual welds like these TiP TiG welds look like automated welds, you know you have selected the right weld process.
The following duplex weld would be considered difficult by any weld shop standards. A ships container made out of 1/4 - 1/2 duplex. The container was for juice transportation so the weld quality was the same requirements as you find in the food and beverage industry. 1/4 to 3/8 fillet welds were typical. The weld surface was to be smooth, weld spatter was a serious issue and the company was so concerned with the weld fumes it was getting from the MIG and flux cored processes it was using that it supplied all the welders with forced air weld shields. The weld in the video is being made with TiP TiG. This weld is in an enclosed area and as you can see the welder has to view the weld from an opening at the top of the part. Note with this high energy 5/16, single pass TiP TiG fillet weld there is no fumes or spatter that are blocking the weld visibility. On a large ship structure, this company got the duplex weld quality it required without weld cleaning, fumes or weld rework. This company no longer uses pulsed MIG or flux cored.
Video 6. TiP TiP, heavy fabrication, ship duplex welds.
If you are welding alloys such as stainless, inconels, duplex, titanium, copper, hastelloys or stelites and you want the best possible weld quality and metallurgical properties without weld clean up, weld fume concerns and without weld rework, take a look in section three and also in the pipe sections.
To view pipe weld and automated weld sections link up with the applications section at the top of the page. Contact Ed Craig any time with email questions email@example.com. For MIG amd flux cored info visit www.weldreality.com.
Section 3. Duplex - Stainless - Inconel - Titanium - Low Alloys - Hastelloys - Cu - Brass - Nickel - Stelite - all alloys or regular carbon steels, there is a simple reason why all code quality applications will benefit from
the TIP TIG process. In contrast to any other weld process,
TIP TIG consistently enables the highest energy agitated welds producing the highest possible weld quality with the lowest possible weld heat. For those of you that are using regular TIG or pulsed MIG, please note you will not attain the weld quality results that will be attained with the TiP TiG process.. Find out more
For seven decades, the regular TIG process has provided the lowest manual weld deposition rates and slowest weld speeds which have in many alloy applications resulted in excess weld heat. It would be an understatement to say that TIG process has been limited in it's weld application potential and few want to use TIG on large applications. With the TiP TiG process its important for the weld shop to realize that the common weld rules and practices that have applied over seven decades to the regular TIG process do not apply to the TiP TiG process. Take a look in this section at more TiP TiG manual weld applications and the extensive weld quality - cost benefits attained
With large weld applications such as this tank, the weld shop wanted to achieve TIG weld quality, however they did not want the TIG weld productivity or weld distortion.
Instead of TIG, Pulsed MIG or Flux Cored, this company used TiP TiG to weld this large stainless vessel.
With a typical TIG labour cost reduction of 250 - 400% with TiP TiG and better weld quality than TIG, Pulsed MIG and Flux Cored. Don't forget with TiP TiG there should be minimal or no weld cleaning, no distortion concerns and no weld fume. and after the X-Rays are complete, you should expect no weld rework.
We can readily demonstrate manual or automated TiP TiG weld process capability:
If your organization has an interest in always attaining the highest possible weld quality with the best mechanical or corrosion properties,in a 30 minute demonstration, (or send us your weld samples and we will video the results), we can show any weld shop that's using the conventional SMAW - TIG - Flux Cored or the Pulsed MIG process, that none of these processes can attain the all position weld quality and weld cost benefits that will be consistently attained with TiP TiG.
Take a close look at the following horizontal, multi-pass welds on a stainless tank. When you evaluate weld process capability, remember, you cannot put a manual TIG torch on a carriage like this without adding a costly Arc Voltage Control (AVC) and if you used Hot Wire TiG the weld would take at least 50% longer than TiP TiG. Also you could not use pulsed MIG or flux cored and make the multipass welds consistently pass 100% X-Rays. In contrast, without the use of Arc Voltage Control, you can put that TiP TiG unit on any carriage or turn table and as with most manual TiP TiG welds, without cleaning in-between the weld passes, consistently meet any code weld quality requirements on any application, any alloy and any weld position.
You cannot put a TIG torch on a carriage which has no Arc Voltage Control and you cannot make these multi-pass alloy vessel welds and guarantee the weld quality with either the MIG or Flux Cored process.
TiP TiG, 200 - 300 % more weld than TIG and 300 - 400% less weld costs than TIG. No arc length (Arc Voltage) controls required, no weld rework or weld fume issues. When did you last see an untouched, gold color weld in a stainless multi-layer weld application?
In the global weld industry, discussions on
Weld Best Practices - Weld Process Controls and Real World Weld Costs are rare subject, and this is an industry that for decades has been welding with four manual processes, SMAW - MIG - TIG - Flux Cored. With this in mind, it should be no surprise to find weld decision makers who will ask,
"why change the way we have always welded”?
Who would weld a ship's Duplex beverage container with TIG? This vessel is approx 30 feet wide with 1/2 - 5/8 average wall thickness?
The reason TiP TiG was used on this large duplex application, was when Flux Cored and Pulsed MIG was utilized, every day there was spatter, lack of fusion, weld porosity, excess weld fumes and inconsistent Ferrite issues. The TiP TiG, all position 7 mm fillet welds were made in a single pass.
Why is the TiP TiG welder using an air helmet for the duplex welds when there are no weld fumes evident? The welders used to make these welds with flux cored and MIG, so the fumes were major issues and the welder were used to wearing the cumberson helmets.
TiP TiG. Safety - Rework - Costs Benefits.
Next time you bid on a code quality carbon steel or alloy weld application, please note.
For every three hours of weld labor required with the regular manual TIG or SMAW process, TiP TiG will produce the same weld production with far superior weld quality and metallurgical properties in less than an hour.
TiP TiG, less pipe skills required than regular TIG and pulsed MIG.
TiP TiG can weld pipes with or without root gaps.
TiP TiG, one process, all position root and - fill passes.
TiP TiG, full penetration, all position welds with smaller pipe - plate edge preps.
TiP TiG, always superior quality than the automated Hot - Cold Wire TIG.
TiP TiG, always superior metallurgical properties.
TiP TiG, less weld cleaning, less distortion, less stresses and always less weld fumes than any weld process.
Video 1. You could not take a Hot Wire TIG process to a turn table and manually weld a pipe or shaft.
Remember this is not only better quality than TIG or Hot Wire TIG, with TIP TiG the weld cost should be at reduced by 200 to 400%
Watch as the welder without feeding a wire or using a foot control (less skills - lower fatigue) produces the cleanest possible welds that will produce the best weld quality. On most multi-pass TiP TiG welds, no weld cleaning required between the weld passes is the norm. Note, in contrast to TIG the TiP TiG weld being produced will have more weld depth, therefore fewer weld layers in groove welds are required. Also if the welders are working with stainless or any alloys, the welders should be exposed to the least possible hexavalant - manganese weld fumes.
Video 2. Its’ not bad when you can reduce pipe weld skills and improve weld quality and productivity.
Note how relaxed this TiP TiG welder is welding a pipe to ASME Sect 9 requirements.
With TiP TiG welds you will reduce arc start - stops and in contrast to pulsed MIG and Flux Cored, provide superior control of these common weld defect locations. Higher TiP TiG weld current (higher, more concentrated weld energy) is enabled from the higher wire feed rates. The faster TiP TiG weld speedsl when combined with Electrode Negative polarity will always result in the lowest possible weld heat. The lowest weld heat, enables the lowest possible weld oxidation producing the cleanest welds. The agitated and higher energy TiP TiG welds enable superior weld fusion. When you use TiP TiG you would reduce the Vee or J groove dimensions with the potential to again reduce your weld costs > 25%. X-Rays are used to find weld defects. Apart from improved weld fusion the TiP TiG welds should always have the lowest weld porosity and inclusions.
As we are all aware, optimum weld quality cannot be determined by a weld inspection criteria that requests visual inspection or partial NDT.
When "optimum weld quality is discussed at this site", it means the ability of a weld process to consistently attain uniform, defect free welds which are subject to stringent 100% X-Ray evaluation. As indicated with this 5G carbon steel fill pass weld on 8 inch pipe, the manual TIP TiG process is used correctly should provide a weld quality, weld continuity and uniformity that is difficult to differentiate from an automated TIG weld.
Today there is only one manual and automated weld process that is capable with any alloys to consistently meet 100% X-Ray or UT weld quality requirements, that weld process is TiP TiG.
Video 3. From pipe to plate. TiP TiG single pass 1/4 duplex fillet.
Section 4. There are certain industries and applications that demand the highest weld - part quality. Nuclear Plants and Submarines - Power Plants - Oil Platforms and Refineries - LNG Constructions - Investment Cast Repairs - Defense & Space Applications - the Food - Processing industry and any applications that weld alloys or require code quality welds. There is only one process that will meet all the manual and automated weld demands, and that process is TiP TiG.. Find out more
If working with a unique weld process that will consistently create the highest weld quality, provide the best possible mechanical - corrosion properties, reduce weld skills, dramatically reduce weld costs, eliminate the need for grinding and cleaning, eliminate distortion and weld rework concerns, and produce the welds with the lowest possible weld fumes and operator fatigue, then you are at the right place. Lets take a look at a few more TiP TiG applications and weld benefits
TiP TiG weldiing 40 inch diameter pipe at the world's largest nuclear construction project.
It does not matter the alloy types - the part thickness, the weld positions, or the scope of the project, with TiP TiG you have a process that will produce;
• Welds with the least distortion.
• Welds with the least stresses.
• Welds with the best mechanical properties.
• Welds with the best corrosion properties.
• Welds with the best impact properties.
• Welds with the greatest control of ferrite.
• Welds with the greatest resistance to cracks.
• Welds with the best weld fusion potential.
• Welds with the least porosity.
• Welds that require the least grinding -cleaning.
• Welds that will produce the least fumes.
Video 1. Perhaps your organization wants to weld or repair armor vehicles or this fighter plane cast engine block.
From Investment castings to alloy aircraft parts, there is only one manual weld process which will produce the highest weld quality with the lowest weld heat.
TiP TiG provides many weld benefits for heat sensitive investment cast repairs or welding Armor plate. The high TiP TiG weld energy ensures optimum weld fusion and the the inert gas and agitating TiP TiG weld always enables the lowest porosity, however the ultimate weld benefit from TiP TiG for all heat sensitive applications, is this process should always enable the lowest possible weld heat. To add to the weld benefits, the TiP TiG process will increase hourly TIG weld production in the range of 200 - 300% while reducing TIG weld costs by > 300%..
All armor steel applications including this Humvee will benefit from a weld process that consistently delivers the highest possible weld quality with the lowest weld heat.
A ten minute weld demonstration is all it will take to show your organization why TiP TiG has to be is a logical choice for any armor steels or cast repairs.
Video 2. When you want the
world’s best automated clad welds, the process choice should be easy.
TiP TiG provides low cost solutions for automated clad welds. Note with this inconel, sub sea clad weld, no Arc Voltage Control was necessary (this is normal Hot Wold wire TIG requirement) and > 250 % more TIG weld deposition was provided.
With TiP TiG, no spatter, lowest possible clad weld heat and lowest controlled weld dilution. No weld cleaning was required between the multi-pass weld layers and the weld shop should have no weld fume issues. The weld shop should always expect with the TiP TiG process, optimum weld clad properties and with machined clad surfaces that contain the lowest possible defects. By the way the low TiP TiG clad weld heat was important with these sub sea pipes, as the multi-pass, two layer welds were made at the pipe ends, locations and the welds had to be made with no interpass temperature control requirements. This sluggish clad weld application presented a poor weld heat sink, an area in which with conventional processes you would have lost control of the clad welds and dilution.
FERRITE LEVELS - IMPACTS - CORROSION - MECHANICALS - IT'S EASY WITH THIS WELDING PROCESS.
When welding alloys that are sensitive to cracks, the first thing to consider is the weld process utilized.
If an organization is concerned about alloys or steels that are crack sensitive, or with attaining specific weld mechanical - corrosion properties, surely the weld solution will come from a weld process that provides the;
(1) the highest possible weld quality,
(2) the lowest possible weld oxidation,
(3) the lowest possible weld heat.
These are the three primary weld attributes necessary to reduce weld crack sensitivity and provide optimum weld metallurgical results :
With the higher TIG weld travel rates from the TIP TIG process, you should always attain the lowest possible weld heat with the smallest possible weld HAZ. Also if required, TiP TiG can produce the widest possible weld joules range. The increased TIG speeds also enable the lowest possible weld dilution which is beneficial for reducing weld cracks or optimum for clad welds.
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 complex alloys, you are reducing weld skills, lowering weld costs, eliminating weld fumes and reducing welder fatigue.
While regular TIG is not suited to those large cryogenic fabrications, however TiP TIG should be the process of choice:
The welding of large LNG vessels with their complex alloys is simple with the TiP TiG process.
The following ship duplex container is completely welded with the TiP TiG process: The ship's container was designed to transport beverage. The top section shown below is approx. 30 foot
(7.5 m) diameter with a typical wall thickness range of 1/4 - 1/2 ( 7 - 12 mm). A prime weld benefit that should be of interest to any QA manager involved in weld heat sensitive parts such as duplex or low chrome steels is
the "semi-automatic" manual TIP TIG process enables the best possible manual welder process conformance to the key essential weld variables that were generated during the weld qualification.
Video 3. Large duplex TiP TiG fabrication.
Small weld heat variations can influence duplex and many other alloy metallurgical properties. On large duplex plate or pipe applications, regular manual TIG weld speeds would be all over the place influencing the high weld heat from the slow weld speeds. With the Pulsed MIG or Flux Cored process, small manual wire stick out variations which are especially common in groove welds, will also have a large influence on the weld heat generated. In contrast the constant fed TiP TiG weld wire should enable the manual welders to produce the closest thing to consistent manual weld speeds. As the TiP TiG wire feed is constantly weld speeds should be near constant.
When you combine the weld benefits from TiP TiG, the manual TiP TiG > 6 mm, single pass fillet welds are just as cost effective as pulsed MIG and flux cored as no weld cleaning or rework should be required and dont forget there are no weld fume issues.
Video 4. TiP TiG on this weld is doing something that regular manual TIG and automated Hot Wire TIG is not capable of.
TiP TiG eliminates the skills and fatigue required to feed a TIG wire and operate the foot weld current control.
Weld that 4 inch pipe root in approx. one minute then increase the hourly TIG pipe weld fill pass production by 200 to 300%. Remember with TiP TiG you have the option of welding that root with or without a root gap. Also the larger, single pass TiP TiG groove weld passes reduce the amount of pipe fill passes required. As a cost bonus you could also reduce the pipe vee prep from 60 - 75 degrees to 45- 50 degrees. Why would you purchase costly weld automation for this tube to plate 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.
Video 5. TiP TiG and manual Tube to Plate welds.
Why waste dollars on costly weld automation when you can most often get superior weld quality with TiP TiG?. The TiP TiG process provides better weld quality than pulsed MIG, manual TIG & automated Hot Wire TIG. The TiP TiG process is typically 100 - 250% faster than TIG. With TiP TiG you will have the lowest weld heat, always the best weld fusion, the least weld pores and the 360 degree welds will be made with one weld start / stop.
Some welds require you regulate the weld speeds, put that manual TiP TiG torch on that mechanized weld carriage or hook it up to your seam welder .
Video 6. Full fusion seam weld without back up.
The application: Weld 1/16 (1.6 mm), 409 Stainless seam weld. To make it difficult a 100% controlled weld penetration was required with no back up bars or weld support.
ulsed MIG failed on this weld and regular TIG was far too slow. The TiP TiG solution, hook up that manual TIG torch to a mechanized carriage and that’s it. In production these full penetration TiP TiG welds will typically run at 30 - 40 inch/min, In contrast to pulsed MIG, less distortion, superior welds, no spatter or weld rework and no fume concerns.
TiP TiG is a manual weld process that reduces pipe weld skills, increase pipe weld
productivity and provides the best possible pipe weld quality.
Video 7. Let the weld quality speak for itself.
Check out the TiP TiG pipe and automated sections to find out why TiP TiG is the world’s best and safest manual and automated pipe weld process.
My buisness partner and good friend Tom O'Malley, tells me I have a tendancy to repeat myself and I admit he is more than correct, (he is more than correct). However, I have been in the weld industry for >50 years and during that time I have watched weld personnel play around with two simple MIG weld controls, (solution at my website, www.weldreality.com) and watched as welders wonder why pulsed MIG does not attain the weld quality desired. I have seen too much weld process confusion in an industry that is saturated with sales advice. I have not got another 50 years to watch this happen with this important process. So I will keep repeating myself and hope you get the message about the important TiP TiG weld benefits,
Who is using TiP TiG?
EXON - HALIBURTON - AREVA - GE - WESTINGHOUSE - BECHTEL - FLUOR - ROLLS ROYCE - AQUILEX - NORTHROP GRUMMAN - SIEMENS - NOOTER - DELTA AIRLINES - TRIUMPH FABRICATIONS - ENERFAB - DIAMOND POWER - BODY COTE and many more.
Dont forget we have a pipe and automated section. Also if you are qualified with TIG you should not need new weld procedures and your qualified ASME TIG welders are qualified with TiP TiG.. Weld question email ed craig at firstname.lastname@example.org.