TIP TIG USA is the exclusive supplier of TIP TIG equipment
in North & South America and Australia.
TIP TIG.
155 9th Ave,
Runnemede.
NJ. O8078. USA.
Phone. 856 312 8164.
TIP TIG weld questions call Ed 828 337 2695.
When you add the TIP TIG process to our unique automated orbital, robot and ossicilator product line, you
will have instant, low cost solutions to attain the best possible automated pipe and clad weld quality.
For info on the TIP TIG 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 TIG process.
TIP TIG SINGLE TORCH ORBITAL EQUIP:
View untouched, world's best, automated pipe welds achieved
with the unique TIP TIG process and our new orbital equipment.
[] Better weld quality than any Hot Wire TIG or regular TIG weld.
[] In contrast to regular TIG or Hot Wire TIG, the TIP TIG process enables 100 - 300% increase in hourly pipe weld production.
[] Easier to use than any orbital TIG equipment.
[] 3 simple procedures for all steels and alloy welds.
[] Lower weld heat than any other weld process ensures cleanest possible welds and lowest possible weld fumes.
TIP TIG TWIN TORCH ORBITAL EQUIPMENT.
BONUS.1. In the time it takes you to get a cup of coffee, you can weld a pipe in a power plant or as the case above, weld inconel clad pipe on a sub sea barge.
BONUS.2.
The weld quality you produce will be superior to that attained with pulsed MIG, regular TIG or Hot wire TIG welds.
For these 8 inch diam, sub sea 3/4 inch wall pipe welds, note that approx. 1 minute was required to set the TIP TIG orbital equipment and approx. 10 minutes to complete the weld the joint. With TIP TIG welds you always produce the highest possible weld quality so there is no need for weld rework. As TIP TIG produces the lowest possible weld heat there is no need to worry about excess weld heat. Exceeding the interpass pass temperatures is rare. Producing the lowest possible weld oxidation, (note the untouched weld color) ensures the welds produced will be the cleanest possible reducing the need for inter pass weld cleaning.
TIP TIG OSSCILATOR FOR WELDS AND CLAD APPLICATIONS:
From the pipe root to the pipe cap, TIP TIG should always delivers the the highest possible manual and automated weld quality
Note the rapid weave oscillation speed for this 30 mm wide TIP TIG weld. What is remarkable about TIP TIG is you can do this with simple, low cost weld automation with AVC or sit a manual welder by the pipe and produce extraordinary pipe manual weld quality at manual weld speeds 200 - 300% faster than your regular TIG welders could achieve
View the untouched weld in the video below..
TIP TIG. NO DEFECTS - NO GRIND - NO OXIDES - NO SMOKE
When you want the best control of weld fusion or clad weld dilution, or the cleanest welds with the least possible internal weld defects, you select the TIP TIG process and achieve those welds with the lowest possible weld heat input.
TAKE NOTE OF THE THE UNUSUAL, UNTOUCHED STEEL WELD CLEANLINESS AND VERY SMALL WELD HAZ .
TO DISCUSS YOUR AUTOMATED PIPE WELD, CLADD OR
HARD FACING
TIP TIG APPLICATIONS, GIVE ED CRAIG A CALL (828 337 2695)
For those contemplating the purchase of traditional Hot / Cold Wire weld equipment or the Liquid Air TOP TIG process, please be aware that in contrast to the TIP TIG process, these automated weld processes are highly sensitive to arc length variations and these processes do not change the TIG weld dynamics. TIP TIG is better suited to most auto weld applications and with TIP TIG you should expect superior weld quality, greater weld productivity with much less robot - automated weld issues.
CONSIDERING TIG WELD OR CLAD AUTOMATION.
Their are many differences between Hot Wire TIG and TIP TIG.
THE HOT WIRE TIG PROCESS HAS BEEN THE AUTOMATED WELD PROCESS OF CHOICE FOR TURBINE WELDS, AIR CRAFT PARTS AND WELDS IN NUCLEAR PLANTS. THIS PORTION OF THE SITE REVEALS THE DIFFERENCES BETWEEN HOT WIRE TIG AND THE TIP TIG PROCESS AND WE ALSO SHOW HOW THE MANUAL OR AUTOMATED TIP TIG PROCESS CAN PRODUCE SUPERIOR CLAD AND WELD QUALITY AND PRODUCTIVITY ON MANY ALLOY WELD APPLICATIONS:
AUTOMATED HOT WIRE TIG INFO: To provide additional energy into the rapid solidifying TIG weld, the
Hot Wire TIG process simply provides a separate AC or DC power source that typically delivers 50 to 100 amps (pre-heats the wire) to a continuous fed weld wire that runs through the torch into a conventional TIG arc.
HOT WIRE TIG IS CONSIDERED A SENSITIVE PROCESS WHEN USED ON COMMON LOW TO MODERATE CURRENT TIG WELD OR CLAD APPLICATIONS:
On low to moderate current Hot Wire TIG applications, the Hot Wire current may only provide a partial weld energy solution to the rapid solidifying, small TIG weld pool.
Apart from the weld current and Hot Wire amps utilized, the weld energy is further influenced by the weld positions, the weld techniques, the arc length variations, the weld wire to tungsten position and distance, the part thickness, the alloys welded and the weld wire size and composition.
The problem with either the automated Hot and Cold Wire TIG process is no matter what type of sophisticated TIG power source is utilized, when using low to moderate TIG weld current, these processes will produce welds with a small fluid weld zone, and the rapid solidifying welds will have low surface tension and have poor receptivity to high wire feed rates.
A rapid solidifying Hot Wire TIG weld will influence the amount of weld wire that can be fed into the weld pool and also influence arc deflection. In the Hot Wire TIG weld current range < 250 amps, which is common for many all position welds and welds on parts < 5 mm, the traditional Hot Wire process is considered a sensitive process and this is the prime reason the automated Hot Wire process is poorly suited as a "manual semi-automatic TIG process".
To reduce the sensitivity to weld wire delivery of over 1.5 lbs/hr,
the TIG weld dynamics have to change.
The regular, automated Hot Wire TIG Weld process is especially sensitive to weld wire delivery when welding or cladding with alloys using the moderate current range of 100 - 250 amps which is typical for horizontal and vertical up welds. For these welds or clad applications, the traditional, automated 0.035 (0.9 mm) HOT wire feed rates will typically be in the 100 - 200 inch/min range. To help maintain a stable arc and uniform weld energy level with automated Hot Wire welds, automatic volt control (AVC) equipment is used to rigidly maintain the optimum tungsten to work distance (arc length).
Note: Automated "Cold Wire" TIG welds simply provide the same weld deposition that a regular manual TIG welder can make.
This is a process that is extremely sensitive to arc length variations and not suited to most manual welds.
With conventional Hot Wire TIG welds, many companies will purchase costly automated equipment to weld seams, deep groove, narrow gap alloy applications or provide bore welds or cladding for valves pipes and other components. From a weld quality perspective the automated, multi-pass Hot wire TIG welds will typically be excellent with small amounts of weld porosity, weld oxide inclusions and the occasional lack of weld fusion. With the sophisticated costly, automated equipment the all position weld speeds will typically be 4 - 8 inch/min.
Traditional Hot Wire TIG Weld Variables:
To enable consistent, controlled melting of the traditional constant fed
Hot Wire into the small TIG arc zone with it's fast freeze, low surface tension weld pool, many variables
require consideration. The variables will influence the wire delivery and the welds and the weld quality and productivity. The variables allow minimal room for change or error.
Common weld variables that affect conventional Hot Wire TIG weld quality and production; [] weld current amount used and changes during the weld,
[] arc
length changes, (voltage variations),
[] tungsten size, profiles and condition,
[] wire feed issues,
[] weld travel speed variations,
[] weld wire to tungsten and weld placement,
[] weld gas flow and coverage, []
inappropriate weld procedure data, [] loor automated weld positioning equipment and lack of effective
equipment maintenance,
[] lack of process control training for all relevant weld / management, supervisors, engineering and weld personnel,
[] lack of best weld practices and lack of appropriate manufacturing instructions on the shop floor,
[] lack of awareness of the sensitivity of the Hot / Cold Wire process for specific welds and weld positions, [] pre-qualified weld procedures made on weld coupons that have little in common to the actual weld joints weld positions, torch angles and part thickness welded.
To reduce Hot Wire sensitivity to weld wire delivery and the many variables listed, it helps if one can
change the weld dynamics and the TIP TIG process provides those changes.
With either manual or automated low to moderate current TIG welds or clad welds, the key weld benefits attained from the TIP TIG process will be;
[a]
TIP TIG changes the weld dynamics which slows the weld solidification and expands the fluid weld area, this simple action reduces the sensitivity to the weld to receiving increased weld wire rates,
[b]
TIP TIG reduces the sensitivity of the tungsten to work distance allowing it to function as a manual process,
[c] TIP TIG always produces superior weld quality which is derived from the increased weld speeds that lower the weld heat and from the agitated welds.
Manual TIP TIG welds can provide higher weld deposition rates than most automated
HOT WIRE TIG welds.
Increased manual / automated TIP TIG wire feed rates allow increased weld current and faster weld speeds. Increased TIG weld energy when combined with the TIP TIG unique weld agitation improves weld fusion potential and reduces internal weld defects.
In contrast to any weld process, the generous weld speeds with the electrode negative polarity TIP TIG process enables the lowest possible weld heat input providing the best possible weld mechanicals or corrosion properties. It's also beneficial with TIP TIG that you will generate the cleanest possible welds from welds that will have the lowest possible weld oxidation potential.
Automated weld equipment and Cost Savings.Before you consider spending a hundred to three hundred thousand dollars on an automated Hot Wire equipment package that utilizes the conventional Hot Wire TIG or Pulsed MIG process, let us show you the weld quality and productivity of either manual or automated TIP TIG welds. We can attain uniform, consistent weld quality for possibly a small percentage of what you intend to invest.
TIP TIG WELD APPLICATION INFO. Contact Ed Craig at ed@tiptigusa.com.
NEW WELD QUALITY AND WELD PRODUCT LIABILTY CONCERNS:
THERE ARE WELD STANDARDS BEING INTRODUCED
IN THE OIL INDUSTRY THAT DEMAND ZERO WELD DEFECTS. WITH ALL POSITION, MULTI-PASS WELDS, ONLY ONE MANUAL - AUTOMATED PROCESS "TIP TIG" HAS THE POTENTIAL TO READILY ATTAIN THAT WELD QUALITY GOAL:
Many weld companies strive to improve their weld quality and minimize weld rework and the liability consequences of failed welds. In the power - oil and defense industries their is decreasing tolerance for any internal weld defects.
One of my clients had a unique Sub Sea Automated Weld Clad Quality Requirement that required "zero weld defects" on their valve bores. The clad welds were made with both inconel and stainless wires. The welds were made with Hot Wire TIG. The surface of the clad welds were machined, often revealing small pore, inclusions and lack of fusion weld defects. The Automated Hot Wire weld defects typically occurred in the valve bores (photo on the right) when the torch rotated and the moderate current welds were made in the horizontal weld position.
In a weld shop it's one thing to have an NDT visual weld standard that allows specific external weld defects, it's an entirely different situation when you have vertical up and horizontal clad bore inconel / stainless welds that require a machined clad weld surface that must be completely free of any visible weld defects.
WHY THE HOT WIRE PROCESS IS OFTEN CONSIDERED A HIGHLY SENSITIVE PROCESS ON
SPECIFIC WELDS AND WHY IT'S NOT SUITED FOR MANUAL ALL POSITION TIG WELDS. With high current > 250 amp Hot Wire automated welds made in the flat position, and the additional Hot Wire current typically 80 - 100 amps, it's easy to maintain a consistent arc length as the plasma in the arc and welds will typically have sufficient size, energy with sufficient weld fluidity to receive high TIG wire feed rates. However when the weld or clad current is less as required for specific horizontal / vertical up TIG welds or when the welds are made on thinner parts, the receptivity of the Hot Wire TIG welds to high wire feed rates is dramatically reduced and the welds can become very sensitive to the many variables that can influence the arc and weld. When the automated Hot Wire TIG process is tried as a "Manual Hot Wire TIG process" the human variables that influence the arc, the weld wire delivery and the weld energy are dramatically increased making the Hot Wire process unsuitable for Manual use. In contrast TIP TIG over comes those sensitivity issues.
For those persons considering Hot Wire TIG, please note on the low to moderate weld current applications, the TIP TIG process also provides Hot Wire current and TIP TIG also provides a unique weld agitation that dramatically changes the weld dynamics. The TIP TIG weld agitation slows down the weld solidification reducing the effects of sluggish alloys, improves weld fusion and reduces internal weld pores.
TIP TIG CAN BE YOUR LOW COST, OPTIMUM, WELD AUTOMATION:
When you have the semi-automatic TIP TIG process and weld parts on a rotary positioner you produce welds with extraordinary weld controls and welds with extraordinary quality and productivity.
Both these welds are made by first time users of the TIP TIG process
At our TIP TIG facility in New Jersey, if you require, we can build or supply you with moderate cost weld automation that enables extraordinary weld quality, however it's also important to note that most of our manual TIP TIG welds will be superior quality than what most automated TIG and Pulsed MIG welds provide.
WHEN YOU WANT TO PROVIDE THE HIGEST CLAD WELD QUALITY
WITH THE LOWEST WELD HEAT CONSIDER TIP TIG.
When automated weld cladding is required, the weld shop has many weld process options. However when "defect free" clad weld quality is required with minimum distortion, there are a few practical weld process options.
PULSED MIG CLADDING.Pulsed MIG is fine for manual welds in which NDT is not applied to the internal weld quality. Pulsed MIG is a great process for external, boiler water wall panel clad welds in which the NDT weld quality criteria is typically weld surface chemistry requirements or visual specifications, however when the inconel or stainless Pulsed MIG cladding is subject to machining, X-Rays or UT examination, this process will likely reveal on many applications that the welds have lack of weld fusion, weld porosity, small pore inclusions and inconsistent weld ties-ins. Pulsed MIG clad welds will also frequently cause distortion and have negative impact on the parts mechanical properties.
MIG SHORT CIRCUIT CLADDING. Short Circuit(SC) is frequently used for clad applications, however SC typically generates many weld issues and should not be used for many "critical clad weld applications" as this process cannot provide weld fusion guarantees especially on parts > 4 mm, also short circuit will frequently produce poor weld tie-ins, extensive weld pore defects and weld spatter.
Note:
Conventional MIG spray transfer is simply too hot for cladding and the high energy spray weld pools are not suited for most vertical up and horizontal welds.
HOT / COLD WIRE TIG CLADDING: In contrast to the available MIG weld modes, the automated Hot Wire TIG process when used for clad welds provides far superior weld quality, however this process as noted at this site when used with low to moderate current and using AVC will still be highly sensitive to many weld variables. That weld sensitivity restricts the wire feed rates utilized which also limits the weld current and weld speeds. Often the automated Hot Wire TIG welds will reveal small pores, inclusions, and occasional lack of weld fusion subjecting the welds to weld rework and further machining. If you would like to improve your clad weld quality, reduce clad weld repairs and improve material flow from the weld shop through the machine shop, please note that the TIP TIG process has the potential to attain a first time manual and automated weld quality never before attained with traditional Hot / Cold Wire TIG or the Pulsed MIG process.
LOW COST TIP TIG CLAD WELD AUTOMATION:
It's this simple, you may be using traditional Hot or Cold Wire TIG for your clad weld applications, however please be aware these processes cannot attain the vertical up or horizontal weld quality / productivity achieved by the TIP TIG process.
Many bore clad welds are made with the inferior MIG short circuit or the Pulsed MIG processes.
The pulsed MIG processes when use for alloy clad welds may;
[a]
provide excess weld heat in the welds and parts causing mechanical, corrosion or distortion concerns.
[b]
create lack of fusion especially with the use of sluggish alloys,
[c]
generate weld porosity or oxide inclusions,
[d]
create weld spatter,
[d]
produce poor weld tie ins.
With the clad equipment shown below typical vertical up TIP TIG clad "weld speeds" on applications as indicated in the photo would be between 15 and 25 inch/min. TIP TIG automated clad welds frequently will not require costly Automatic Height Controls (AVC) for the tungsten to work setting or other sophisticated equipment. No matter how complex the weld application or the alloy welded, with TIP TIG the weld procedures will be both few and simple.
TIP TIG Automated Stainless - Inconel Cladding.
Highest Quality at Lowest Costs
TIP TIG: LOWEST WELD HEAT INPUT. NO SPATTER. NO LACK OF WELD FUSION. NO ARC VOLTAGE CONTROLS. CLEANEST WELDS WITH NO REQUIRED WELD REWORK AFTER 100% X-RAY.
TIP TIG WELD AUTOMATION PROVIDES NUMEROUS WELD - CLAD BENEFITS:
In contrast to regular Hot Wire TIG, Short Circuit MIG and Pulsed MIG, with TIP TIG automated clad
welds, an organization will have a weld or clad operation that can attain numerous weld benefits.
[1] In contrast to regular Hot / Cold wire TIG, with the TIP TIG automated process, the weld puddle dynamics are dramatically changed.
The TIP TIG increased wire feed rates enable increased TIG weld current which combine with the TIP TIG hot wire current and unique weld pool agitation. The resulting larger TIP TIG fluid weld area enables an increase in weld production. The faster weld speeds that result dramatically can reduce weld heat input. With TIP TIG you would expect superior, multi pass TIG weld quality with less weld pores, less inclusions and improved weld fusion.
[2] In contrast to conventional low to moderate current, Hot wire TIG clad ID or OD welds, TIP TIG should
readily allow a 50 - 100% increase in weld deposition rates which apart from the obvious
labor saving costs also dramatically reduces the weld heat input. The faster TIP TIG weld speeds may also provide superior mechanicals and less distortion..
[3] You can use pulsed MIG and short circuit for clad welds, however you may be delivering to your customer a product that has lack of fusion, weld pores, poor weld tie-ins and the parts will often be subject to excess weld heat.
[4] When ever
you deal with a company that provides welded components to the oil industry you typically will find in that company has numerous weld
procedures. When you set your clad welds with the TIP TIG process you likely will not require more than three
sets of weld parameters for all possible weld or clad applications.
With TIP TIG increase the automated TIG wire feed rates, provide superior
welds and mechanicals while dramatically reducing the part weld heat input.
Multi Port Flow Diverter. Material Super Duplex. Euro Weld ER2594 2" Sch 80.
The company welding these parts would typically use costly AMET equipment with Hot Wire TIG, they now use the TIP TIG process and have attained dramatic improvements in both weld productivity and quality.
You can use the world's most costly, sophisticated, automated and Hot Wire weld equipment, however
if you want to increase your auto weld productivity by one to four hundred percent and improve both the weld quality, mechanical and corrosion properties, give consideration to TIP TIG.
Question on Automated Hot Wire Welds:Ed. in January 2007, we installed two AMET Inc. XM machine automated Hot Wire GTAW systems on which I have programmed over 500 weld pass programs, both cold and hot wire, for non-nuclear applications. The biggest issue we have with hot wire GTAW is "keeping the weld wire in the very small sweet spot". Would TIP TIG reduce this wire to arc sensitivity?
Regards Frank. Diamond Power.
Answer. Frank with the TIP TIG process you would have the opportunity to use a TIG process with much less concern for locating the wire tip into the very small rapid solidifying weld sweet spot.The TIP TIG agitated weld puddle expands the fluid weld area improving the wire to weld receptivity and also improves the weld quality.
Note:
An important benefit of the TIP TIG weld agitation is that there is minimal concern for welding sluggish alloys like Duplex, Chrome, Nickel or High Carbon Alloys. On these and all sluggish alloys TIP TIG has the potential to provide superior side wall fusion and less weld porosity.
FOR
COMPLETE TIP TIG DESCRIPTION,
visit the TIP TIG home - manual pages
of TIP TIG.
TIP TIG and a low cost $800 rotary positioner producing the
highest automation weld quality and productivity.
IF MIG OR FLUX CORED MEETS YOUR DAILY WELD QUALITY REQUIREMENTS, IT MEANS
YOU ARE NOT CONCERNED WITH INTERNAL WELD QUALITY AND YOU DON'T NEED TIP TIG.
TIP
TIG Weld Quality: The TIP TIG process will provide your organization with the manual and automated
capability to attain weld and clad quality levels way beyond the conventional TIG
- Hot - Cold Wire TIG - Pulsed MIG and the Flux Cored process.
Application:
Automated TIP TIG on 2205 Duplex Industrial heating boilers that are 0.035 - 0.045
thick. Only applies to over lap welds in this thickness range. Full penetration, defect free welds were required on these very thin gage duplex boilers shown in the left photo. The traditional automated Hot / Cold Wire TIG process was used for these duplex welds. While the parts were very thin. the duplex welds were sluggish (examine the irregular weld surface in photo). The poor weld wetting and weld irregularities influenced small pore porosity, weld fusion consistency and the weld travel rates that could be utilized. The
customer typically attained a maximum Hot Wire TIG weld travel speeds from 12 - 15 inch/min.
The automated duplex tank welds were switched from Hot Wire TIG to the TIP TIG process. The TIP TIG weld
parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire. The TIP TIG data is as follows:
TIP TIG Weld Current : 190 Amps
TIP TIG Weld
Voltage: 12.5 Volts
TIP TIG Travel Speed: 35 inch/min.
Darren the UK TIP TIG Engineer reported,
"the time we had at the tank facility was limited to a few hours. I think with a more time we could
develop the TIP TIG weld procedure to readily exceed 45 inch/min providing a 200% increase in weld travel. The
customer stated the TIP TIG duplex welds in right photo were defect free, the welds had a superior, less sluggish weld bead
appearance and the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP TIG process was much more stable and consistent.
Application:
Automated TIP TIG
Vacuum boiler parts.
Material:
Carbon steel.
Material thickness: 0.050 to solid rod.
TIP TIG Weld speed: 18 inch/min
This full penetration vacuum application required defect
free welds and the regular automated Hot and Cold wire TIG provided instability and inconsistency resulting in unacceptable weld quality. A change to TIP TIG dramatically increased the weld travel, eliminated all weld issues and established consistent weld quality and productivity.
Every weld engineer
and technician knows the difficulty with attaining
perfect weld quality on small round code quality
applications like this.
TIP TIG IS EASY TO AUTOMATE AND SHOULD PROVIDE A
WELD QUALITY NOT ATTAINABLE WITH ANY OTHER PROCESS
TIP TIG DOES NOT HAVE THE WELD ISSUES ASSOCIATED WITH HOT WIRE TIG WELDS .
TIP TIG AUTOMATED WELDS
ON
HYDRAULIC PARTS.
Instant high weld energy is always beneficial on small round welds where there should always be concern for the weld fusion and the weld tie-ins. The focused, TIP TIG arc plasma and agitated weld will provide superior weld fusion than pulsed MIG.
The TIP TIG hot wire current and weld puddle agitation will reduce weld porosity potential. Note the TIP TIG weld speed for the 6mm fillet, a weld speed that should remind you of a MIG fillet weld.
TIP TIG typically did not require arc voltage control equipment. Simply add a Bug-O or rotary positioner to the TIP TIG process and you have fully controlled automated welds that provide the best possible weld quality.
Note the weld smoke is from the drilling lubricants on the parts.
CONSISDER TIP TIG WHEN YOU NEED QUALITY
BEYOND REGULAR TIG OR PULSED MIG
TIP TIG always OPTIMUM WELD QUALITY at MIG speeds.
Low Cost Automation. 17- 4PH Base Material Weld Sample welded with TIP TIG
OIL INDUSTRY PART. 60 TIP TIG WELD PASSES WITH NO INTER PASS CLEANING, NOTE THE LACK OF DEFECTS THE
GOOD WELD FUSION AND SMALL WELD HAZ.
TIP TIG WELDS A DEEP "J" GROOVE 17- 4PH JOINT WITH ER630, 035 WELD WIRE. THIS MANUAL / ROTARY TIP TIG WELD IS MADE 300% FASTER THAN MANUAL TIG. MINIMAL WELD CLEANING AND ZERO REWORK.
TIP
TIG automated
stainless
or duplex heavy wall tanks:
Tank Wall Thickness 15mm.
TIP TIG Weld speed: 16 inch/min
How many companies would consider the TIG process a practical process for welding a 15 or 25 mm stainless or duplex tank or pressure vessel?
What you attain here from the TIP TIG process, is
from the root to the cap pass you will achieve first time, defect free, horizontal vee groove welds made at moderate average weld speeds
of approx 16 inch/min. You could readily achieve this weld speed with pulsed MIG or flux cored, however the
question would be how confident would you be that the MIG and flux cored radiographs
or UT will not find weld defects.
On applications like this duplex tank, the TIP TIG process should deliver x-ray quality welds with zero weld rework. For those interested in cost reduction this tank was not purged with any gas and no back gouging or grinding was required for the open root. The TIP TIG 2 side root weld method was used. For details email Ed ed@tiptigusa.com.
TIP TIG robot brazed weld that required
superior cosmetic weld surface:
TIP TIG robot success
from the UK Cyberweld company. Robot MIG brazing was used on the Jaguar X150. A robot system
with vision guidance had been installed to perform this MIG weld on the Jaguar
roof joint. As this was a visible weld, the quality of the finish was critical
and the system supplier had not been able to achieve the braze quality required
by Jaguar despite working on the problem for a number of months with pulse MIG and other processes. Within a few
hours for the weld set up, TIP TIG provided a consistent weld quality never before
seen by Ford.
GREAT WELD AUTOMATION EQUIPMENT WILL NOT ENHANCE
A WELD PROCESS THAT IS POORLY SUITED TO THE WELD AUTOMATION:
For decades many
robot integrators lacked confidence with the Hot Wire TIG
process. These companies have found on many robot welds, clad
or brazing applications, that the Hot Wire process was extremely sensitive to many weld variables and tight controls were necessary but difficult to maintain.
TIP TIG finally provides a process thats comfortable on a robot. At the 2010 AWS weld show, many companies were proud to exhibit their automated pipe weld equipment with the Hot / Cold Wire TIG process
welding in the 5G position with typical 0.035 wire feed rates set 60 to 140 inch/min and weld travel rates at the low, high heat input of3 - to 6 inch/min.
The automated TIP TIG process is in contrast to the
traditional automated Hot / Cold wire TIG process, is a much more robust process. With
TIP TIG orbital or manual all position welds on any carbon steels or alloy pipe 5G welds, the fill pass wire feed rates will typically be 120 - 280 inch/min. Think about the weld quality / production benefits and the dramatic reduction in the weld heat generated.
TIP TIG on Hastelloys - Duplex - Stainless - Inconels or any Alloy seam welds, simply add TIP TIG to that seam welder and dramaticlly increase weld production with superior weld quality.
Advantages from automated TIP TIG welds.
[]
TIG TIP welds with higher deposition rates than traditional manual TIG and also with higher deposition rates than many automated Hot Wire TIG applications reducing
weld labor costs.
[] TIP TIG uses standard 30 - 40 lb
MIG wire spools reducing TIG wire costs and with the increase in weld speed look for a dramatic reduction in argon gas costs.
[] TIP
TIG welds are less sensitive to the issues that occur with conventional automated Hot
/ Cold wire TIG applications.
[] TIP TIG faster weld speeds and the agitated welds can provide superior weld quality with lower heat input that can result in reduced
distortion, less oxidation, cleaner welds with less weld stresses.
[] TIP TIG welds provide superior side wall weld fusion reducing lack of fusion defects and often enabling a reduction in Vee or J groove
weld
edge preparation, dramatically reducing labor and consumable costs.
[] TIP TIG should always produce the lowest weld fumes and as weld grinding should be rare, less contaminated particles in the air.
[] TIP TIG will dramatically reduces arc start / stop
weld defects, which are common with pulsed MIG, flux cored and traditional TIG.
[] TIP TIG in contrast to all MIG spray
and pulsed MIG welds, can provide far greater control of small welds < 5mm.
ED'S MANUAL AND ROBOT WELD PROCESS CONTROL RESOURCES.
ED OPTIMIZED ROBOT WELDS FOR HUNDREDS OF COMPANIES.
A FEW OF HIS PROJECTS, THE FORD F150 FRAMES -
VOLVO CABS - CORVETTE FRAMES-
HARLEY FRAMES - NEW BEETLE SEATS AND
THE WELD'S ON CATERPILLAR
WORLD'S LARGEST TRUCK.
To witness the extraordinary TIG weld Quality and Productivity improvements from the
TIP TIG process on carbon steels, duplex, stainless, Titanium, Hastelloys or any alloy applications, we invite you to contact us to set an appointment for a visit at our New Jersey facility. You may want to send samples for welding in advance.
e-mail Nick at nick@tiptigusa.com or call Nick at 856 312 8164.
We are looking for TIP TIG dealers for
distributors for Canada, Texas and Brazil.
EMail Tom at tom@tiptigusa.com
Australia. TIP TIG sales, workshops or weld demos contact;
Brad Thomas. SFI Australia
Direct 03 5332 5312 Tel 1800 734 000
Fax 03 5338 2033 Email brad@sfiaust.com.au.
Web site. www.sfiaust.com.au
Weld Questions Ed Craig E-Mail ed@tiptigusa.com
To find out
more on controlling manual
and robot
MIG or Flux Cored
visit weldreality.com the worlds largest web site
on MIG and Flux Cored Weld Process Controls
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 weld application questions, phone Ed. Craig day or evening,
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.
TIP TIG.
155 9th Ave,
Runnemede.
NJ. O8078. USA.
Phone. 856 312 8164.
A FEW OF THE COMPANIES WHO HAVE PURCHASED THE TIP TIG PROCESS
OR ATTENDED THE TIP TIG OPEN HOUSE AND WORK SHOPS .
AREVEA - EXON - WESTINGHOUSE - WELDING SERVICES - KELLY CONSTRUCTION - TI-FAB - DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE CONTRACTING - FLUOR - BECHTEL -TRIUMPH FABRICATIONS - SIEMENS - ROLLS ROYCE - ENERFAB - DIAMOND POWER - EXON - NOOTER - BODY COTE - SPACEX - NORTHROP GRUMMAN - SIEMENS AND THE "UA" THE LARGEST PIPE FITTERS UNION IN THE THE USA IS PLACING THIS PROCESS IN THE MAJORITY OF IT'S TRAINING FACILITIES.
AUTOMATED HOT WIRE TIG INFO: To provide additional energy into the rapid solidifying TIG weld, the
Hot Wire TIG process simply provides a separate AC or DC power source that typically delivers 50 to 100 amps (pre-heats the wire) to a continuous fed weld wire that runs through the torch into a conventional TIG arc. 
[] weld current amount used and changes d
Manual TIP TIG welds can provide higher weld deposition rates than most automated 
PULSED MIG CLADDING.
LOW COST TIP TIG CLAD WELD AUTOMATION:
Answer. Frank with the TIP TIG process you would have the opportunity to use a TIG process with much less concern for locating the wire tip into the very small rapid solidifying weld sweet spot.
Application:
Automated TIP TIG on 2205 Duplex Industrial heating boilers that are 0.035 - 0.045
thick. Only applies to over lap welds in this thickness range.
The automated duplex tank welds were switched from Hot Wire TIG to the TIP TIG process. The TIP TIG weld
parameters and speeds were achieved using an 0.035 (1mm) 2205 Duplex wire. The TIP TIG data is as follows:
Application:
Automated TIP TIG 
Tank Wall Thickness 15mm.
