TIP TIG Manual Welds.

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 USA sells and services unique, cost effective manual & automated pipe - fabrication weld - cladding - hard facing 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 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.

 

Ed despite his bad back and arthritis, welding
a 3/8 (9 mm) Super Duplex TIP TIG fillet.

With this TIP TIG weld, in contrast to regular TIG, we are attaining 250 - 300% more TIG weld each hour. Note the weld cleanliness and the exceptional weld quality. Examine the small HAZ, the lack of oxidation, the lack of spatter, the minimal weld fumes. Every TIP TIG manual or automated weld should meet a 100% X-Ray weld quality requirements.

 

 

A GOOD WAY TO SHOW SOME OF THE TIP TIG ALLOY WELD BENEFITS, IS TO FOCUS ON WHAT TIP TIG CAN ACHIEVE WHEN WELDING A COMPLEX ALLOY SUCH AS TITANIUM, (HIGHLY SENSITIVE TO WELD HEAT AND OXIDATION). The following video shows TIP TIG welding titanium "without the use of a Gas Trailing Shield". What is important about this titanium TIP TIG weld application, is there is no other manual weld process that is capable of producing the weld shown in the video below.

HOW TO ATTAIN SUPERIOR TITANIUM WELD QUALITY AND PRODUCTIVITY THAN THAT ATTAINED WITH REGULAR TIG. When welding costly, complex Titanium alloys, using a weld process that consistently produces optimum weld quality with the lowest possible weld heat has to be a great benefit. Take your best regular TIG weld on any titanium application and we will show you on any manual or automated welds, that the TIP TIG process will deliver superior weld quality with 100 to 400 % faster weld travel rates. The faster TIP TIG weld travel rates dramatically lowers the electrode negative TIG weld heat, which of course reduces the concern for the weld oxidation influence. Also with the TIP TIG unique weld puddle agitation, think about the reduction in small pore weld defects which is common in titanium welds. Examine the untouched, TIP TIG titanium silver weld color on video (below). The optimum color was attained without using a gas trailing shield. Note: Depending on the weld application and specification utilized, Silver - Straw - Bronze - Brown can be acceptable. With TIP TIG welds, the titanium weld wire tip is always in the TIG arc sweet spot, and even at the weld completion the Titanium wire tip is protected from oxide formation by the post shield gas. Apart from the Titanium wire savings you will achieve from using MIG reels, think about the common TIG weld wire waste you will prevent, no more oxidized, expensive wire cut offs sitting in the scrap. Typically 10 - 15% of regular TIG wire ends up as scrap. Thanks to the higher TIP TIG weld speeds, we made the following TIP TIG welds on Grade 2 titanium, 3/16, (5 mm) parts without using a gas trailing shield. We achieved the untouched bright silver weld without any indication of oxide contamination on the welds or on the back side of the part. I am not recommending not using a trailing shield for all titanium welds, I am simply showing those interested in welding Titanium, that when you use the TIP TIG process, the conventional trailing gas shield may not be necessary especially on parts > 4 mm. Also with or without a gas trailing shield, with TIP TIG, you will always achieve superior weld quality than the regular TIG or any other weld process.

TIG versus TIP TIG weld Titanium Video.

If video pauses let it play through and repeat, usually better the second time.

TRADITIONAL ORBITAL TIG DATA WHEN WELDING GRADE 2 TITANIUM.	MANUAL TIP TIG VIDEO WELDING GRADE 2 TITANIUM.
Regular TIG: Typically all position, manual or mechanized titanium TIG welds on parts > 3 mm will be carried at weld speeds in the 3 to 6 inch/min range. To protect the low speed, high heat welds, trailing shields are a critical weld requirement to minimize the effects of oxidation. When welds are sensitive to oxidation you know weld rework and weld porosity will be an issue.	TIP TIG: Depending on the part thickness, TIP TIG manual weld speeds on Titanium parts will typically be 12 to 45 inch/min. The above 3/16 (5mm) TIP TIG lap weld was made at 24 inch/min. If your organization uses regular TIG on Titanium, you will be pleased to know that with TIP TIG, most manual or automated titanium welds will typically be done 200 to 400% faster and always provide superior weld quality.

 

 

 

THE BENEFITS THAT TIP TIG BRINGS TO TITANIUM WELDS ARE THE BENEFITS
A WELD DECISION MAKER COULD APPLY TO ANY HEAT SENSITIVE ALLOY.


When you can consistently produce the highest weld quality
with the lowest weld heat you will provide extraordinary alloy weld benefits.

TIP TIG enables the lowest weld heat (lowest weld joules) for any alloy welds: The TIP TIG process is not a process based on electronic bells and whistles or exaggerated sales claims. As we are all aware, the regular TIG process utilizes electrode negative, (EN) which is beneficial for weld heat reduction as the electron transfer from the tungsten tip to the work it dissipates the majority of the weld heat into the part, however as noted many times in the TIP TIG home page, the Achilles heel of the regular TIG process, is the process provides the lowest low weld deposition rates producing very low weld travel rates. Typically TIG travel rates are in the 2 - 8 inch/min range. The slow TIG weld speeds generate the high weld heat input. In contrast to regular TIG, the TIP TIG process provides much greater weld deposition rates producing faster TIG weld speeds. Typical manual TIP TIG weld speeds are in the range of 10 - 40 inch/min. In contrast to all other weld processes, when you combine the increased TIP TIG weld speeds with the EN polarity benefits, you should always attain the lowest attainable weld joules. The dramatic joules reduction with TIP TIG produces welds that will have the least weld distortion, welds with the lowest oxidation and the welds will always produce the smallest possible weld heat affected zones (HAZ). In comparison to Pulsed MIG - Flux Cored and regular TIG welds, when using the TIP TIG process, you can typically expect a weld joules reduction in the range of 50 to 200%.

 

While many companies look to costly automation to improve their weld quality,
with the semi-automatic, manual TIP TIG welds you can consistently meet
the requirements to attain zero defects with 100% X-Ray requirements:

TIP TIG DRAMATICALLY REDUCES THE CHALLENGES ASSOCIATED WITH WELDING ANY COMPLEX ALLOYS: Numerous global weld shops daily face the challenge of welding complex, heat sensitive alloys or welding applications with stringent weld code quality requirements. The challenging weld applications can be as varied as welding pipes or valves in a nuclear plant, turbine parts, sub sea valves or the exhaust on the latest fighter plane. When welding demanding alloy applications, managers strive to avoid costly weld rework, costly material replacement and unnecessary material handling or machining. Weld managers, supervisors and engineers will be glad to know that in contrast to all other available manual or automated weld processes, the TIP TIG process will always provide the highest possible weld quality with the best metallurgical results. NO MATTER WHAT THE ALLOY WELDED, EXPECT THE BEST WELD QUALITY WITH THE LOWEST WELD HEAT FROM EITHER THE MANUAL OR AUTOMATED TIP TIG PROCESS. COPPER TO STAINLESS. On the right a 3/8 wall (9.6mm), 10 inch (25 cm) diameter copper to stainless pipe. No pre-heat. Weld wire 0.035 (1mm), ErCuNiAI (Amptrode 46). First attempt with TIP TIG. COPPER TO STAINLESS TIP TIG WELD BENEFIT, FASTER TIG WELD SPEEDS. Including the root this weld required 3 TIP TIG weld passes. The complete TIP TIG weld cycle time including the root was approx 200%\ faster than that attained by the regular TIG welders. COPPER TO STAINLESS TIP TIG BENEFIT, LESS WELD DEFECTS. Note the fluid weld energy on these alloys that typically produce very sluggish welds. The improved weld fluidity was possible as TIP TIG enables higher wire feed rates which allow for higher weld current than that typically attained with a manual TIG welder. Also the TIP TIG hot wire current and weld agitation further slows down the weld solidification providing superior side wall fusion and less pore defects than that possible with regular TIG on either Cu or stainless. The customer appreciates a process that requires no weld rework. COPPER TO STAINLESS TIP TIG BENEFIT, CLEANER WELDS WITH LESS FUMES. This weld is untouched, note the weld cleanliness and the lack of oxidation from the faster TIG weld speeds The cleaner TIP TIG welds will have lower pore / inclusion defects than that possible with regular TIG, and less brushing and grinding will be required. Also always expect the lowest possible weld fumes. CONSIDERING PURHASING COSTLY COMPLEX HOT WIRE TIG - PLASMA OR LASER WELD AUTOMATION? Any manager working with code quality welds or welding costly alloys will want to attain optimum, consistent, manual weld quality with good productivity. That same manager would likely also believe that the weld process selected should have the capability to attain consistent weld conformance with those pre-qualified weld procedures. With TIP TIG the addition of a simple turn table - automated weld carriage, or a simple bore welder shown below will lead to remarkable automated weld quality with low weld heat input. For more on weld automation visit the TIP TIG Automation Section.

 

TIP TIG USED FOR CLAD INCONEL WELDS IN A STEEL BORE. NO ARC VOLTAGE CONTROL AND TIP TIG PROVIDES SUPERIOR QUALITY TO BOTH HOT WIRE TIG & PULSED MIG.

Less weld heat, less distortion, cleanest welds with less weld defects, less concern for sluggish alloys like duplex and stainless, better weld fusion than MIG and regular TIG, least fumes, good deposition rates and of course low weld costs.

 

 

 

 

A FEW OF THE TIP TIG WELD EQUIPMENT BENEFITS FROM THE PATENT PENDING TIP TIG PROCESS. [1] The TIP TIG torch provides a "constant fed weld wire which is consistently fed into the optimum arc and weld position. [2] The TIP TIG Hot Wire power source provides current to pre-heat the weld wire adding to the energy in the TIP TIG welds. [3] The unique patented TIP TIG wire feeder provides a unique mechanical action on the weld wire that agitates the weld pool. The agitation changes the weld dynamics as it slows down the weld solidification and enables more wire to be fed into the weld pool. The increased deposition, the increased weld current and agitated weld pools provide many TIG weld quality - productivity benefits. [4] TIP TIG weld current is generated typically by a 350 - 500 amp TIG power source that has the 4T or 2T ability to communicate with the TIP TIG torch TIP TIG. WELD PROCEDURES & WELD QUALIFICATION, AN IMPORTANT POINT WORTH REPEATING: Watch three highly skilled manual TIG welders weld the same part. Watch as they manipulate their regular TIG weld wire and you will note the weld skill differences, the different techniques in feeding the weld wire and the variable low wire feed rates. The subtle weld differences between each manual TIG welder and the many arc start / stops required by the regular TIG process usually contribute to the TIG pipe weld defects found with NDT. Also the high weld heat input from slow manual TIG weld speeds is often the prime cause of cracks, distortion. mechanical or corrosion issues.

TIP TIG SUPERIOR WELDS ON ANY METAL,
ANY THICKNESS, ANY POSITION.

[] With TIP TIG you take the slow inconsistent manual wire feed rates out of the TIG process and eliminate numerous arc starts. [] With TIP TIG you have the capability to control the torch with one or two hands and you do not need a foot control. [] With TIP TIG you can attain MIG deposition rates.

QA Management will be glad to know


that with the TIP TIG process you can reduce weld issues,
weld rework and simplify weld procedures.

THREE TIP TIG SIMPLE WELD SETTINGS FOR ANY WELD, ANY METAL, ANY WELD POSITION: To operate TIP TIG process you simply set the weld current on the regular TIG power source and set the TIP TIG wire feed rate to one of three common TIP TIG wire feed - current settings that are applicable to most weld alloys and most all position weld applications. Note: From a global weld code perspective, TIP TIG would be considered a "Hot Wire TIG process" however please remember that due to the unique mechanical action on the weld wire, TIP TIG is superior to Hot Wire TIG.

Welding Chrome Moly Steels: None of the following weld processes, regular TIG - Pulsed MIG or Flux Cored can provide the manual, all position weld quality that TIP TIG will deliver. TIP TIG weld agitation produces less weld pores. TIG TIG is not concerned with sluggish alloys and TIP TIG will always attain superior weld fusion. Thanks to the increased TIG weld speeds, TIP TIG has the potential to lower weld distortion, produce the cleanest welds, produce welds with the smallest HAZ and the best mechanical / corrosion properties.

Welding - Cladding - Hard Facing complex - heat sensitive alloy applications.

When you provide the best all position weld quality at the lowest possible weld
heat you have the ultimate weld solution for the world's most complex alloy welds.

Ed in photo wishing he had TIP TIG when managing a contract in Thailand with
Textron & the Thai Army to repair cracks on the 270.000 tensile, USA Textron Tanks.

High Strength Steels or Low Alloy Steels: None of the following weld processes, regular TIG - Pulsed MIG or Flux Cored will provide the weld quality that TIP TIG can provide. Also with high strength materials, remember TIP TIG will always produce the lowest possible weld heat, the smallest weld HAZ and therefore consistently produce the best mechanical properties.

TIP TIG EQUIPMENT IS EASY TO MAINTAIN: Maintenance supervisors will be glad to know that TIP TIG equipment does not utilize sophisticated electronics and the small portable TIP TIG weld units are readily adapted to most modern 350 - 500 amp TIG power sources that have the ability to communicate with the TIP TIG torch. TIP TIG is easily adapted to automated weld equipment including robots. TIP TIG can utilize both air and water cooled torches, however as TIP TIG uses higher weld current than TIG with extended weld duty cycles, water cooled torches are most common. With TIP TIG you do not require a foot control. Welders can make good use of their TIG skills with TIP TIG and benefit from the use of one or two hands on the torch. With the constant fed wire feed and two hands on the TIP TIG torch, most manual TIP TIG welds should look like and have the quality of automated TIG welds. Please Note: Do not confuse TIP TIG with any other global Hot / Cold TIG automated or manual TIG weld systems. Your North American weld personnel may say they have tried this technology, if they do they are confusing TIP TIG with other hot or cold wire manual or automated systems that simply cannot compete with this process. The TIP TIG process has only been in North America since Sept. 2009 and this is the only available global TIG process that physically changes the TIG weld pool.

TIP TIG welding Duplex, Super Duplex & Stainless: None of the following weld processes, regular TIG - Hot / Cold Wire TIG - Pulsed MIG or Flux Cored can provide the weld quality that TIP TIG can deliver. With the unique combination of Hot Wire current and the TIP TIG weld pool agitation Duplex Inconel and Stainless welds are much less sluggish and weld fusion and porosity / inclusion issues should be less of a concern. TIP TIG is also the optimum process for welding duplex pipe root welds in any weld position as TIP TIG dramatically lowers the weld heat producing the lowest possible weld joules and therefore lowering concerns for attaining optimum ferrite levels and impact properties. With TIP TIG on any alloy, the mechanical and corrosion properties will always be optimum from a weld process that always provides the best possible weld quality with the lowest possible weld heat input. From Jeremy TIP TIG. Edmonton. Ed: Reference the Alberta Cold Lake - Tar Sands Duplex Weld Coupon results. We received the TIP TIG weld test results on the 10” duplex coupon that I welded in April. The customer reports that he has never seen duplex weld / ferrite / mechanical results as good as these. Note duplex ferrite results are reported in the pipe section.

NO WELD AUTOMATION REQUIRED WITH TIP TIG
TO ATTAIN AUTOMATED WELD QUALITY:



TIP TIG 3/8 (9mm) SUPER DUPLEX BUTT WELD.

1/8 (3-4 mm) gap. TIP TIG welds Super Duplex, note the weld control and note no foot control. 300 - 400% faster than regular TIG. Always superior weld quality than regular TIG and always expect zero rework on 100% X-Ray welds.

 

 

TIP TIG 3/8 VERT UP SUPER DUPLEX:

TIP TIG 7 mm fillet vertical up weld on super duplex

TIP TIG, ONE PROCESS FOR ANY THICKNESS.
ONE PROCESS FOR ANY ALLOY AND ANY WELD POSITION.

APPLICATION: SMALL DIAMETER STAINLESS TUBES TO SHEET: For the smaller diameter stainless tube welds shown on the right, the easy to use TIP TIG process enabled the welder to use "two hands" on the light weight torch to provide ultimate manual control of the TIG torch as it went 360 degrees around the small tubes. Heat exchanger material: 1.4571 Tube Diam 3/4 inch (18mm). 2 layer weld required. Welds must be defect free. TIP TIG Weld time: 14 sec/weld. On these TIP TIG tube to sheet welds, note the weld tail on each weld. The tail was a customer requirement to keep arc starts / stops out of the welds. This manual TIP TIG welder benefited from using two hands on the torch and the controlled, constant wire feed rate generated an automated weld appearance. The welds were done 2 times faster than regular manual TIG. The resulting TIP TIG weld quality was superior to the manual TIG and pulsed MIG welds previously applied. The TIP TIG welds produced the lowest distortion and were 100% defect free. One thing companies need to consider instead of purchasing costly orbital, automated equipment for applications like this, they can get the same quality and productivity with a manual welder and the TIP TIG process..

 

Tube to sheet. Manual TIP TIG delivers
welds with automation quality.

WHEN EXTRA TORCH CONTROL IS BENEFICIAL, TIP TIG ENABLES TWO HANDS ON THE TORCH CREATING WELD UNIFORMITY AND CONTINUITY ON THE TUBE TO SHEET WELDS, A QUALITY SIMILAR TO AUTOMATED WELDS.

VIEW WELD BENEFITS THAT ARE SIMPLY IMPOSSIBLE TO ATTAIN UNLESS YOU USE TIP TIG

CARBON STL TIP TIG 2 G PIPE ROOT.	CARBON STL TIP TIG 2 G PIPE FILL.
With TIP TIG attain the same uniform, consistent, optimum root weld quality from the 6 to 12 o'clock positions. With TIP TIG you dramatically reduce weld starts / stops and will attain cleaner, less oxidized root and fill passes. With the continuous wire feed, all TIP TIG root welds are made 50 to 80% faster than regular TIG while the fill passes are typically 100 - 400% more wire.	SUPERIOR SIDE WALL FUSION FROM THE TIP TIG AGITATED WELD WETTING Less oxide formation leads to cleaner welds with less pores and inclusions. With TIP TIG root - fill passes, the reduced weld start / stops typically required from 6 to 12 o'clock enable a weld quality uniformity impossible to attain with regular manual TIG or pulsed MIG.

Visit the TIP TIG pipe section for extensive pipe info.

Austenitic - Martensitic - Ferritic Stainless Steels: None of the following weld processes, regular TIG - Pulsed MIG - Plasma or Flux Cored will provide the weld quality that TIP TIG will deliver. A ten minute demo will prove that when welding chrome nickel alloys, TIP TIG will always produce the lowest weld heat input, the least weld distortion, the lowest oxidation, the best weld fusion and the lowest porosity potential. The TIP TIG benefits lead to the lowest weld rework and TIP TIG should always deliver the best possible mechanical and corrosion properties.

TIP TIG AND SUPERIOR ALL POSITION WELD QUALITY. In a 30 minute hands on demonstration at our Philadelphia facility, the TIP TIG team can show you on any pipe, plate or manufacturing application how in contrast to any other weld process that TIP TIG will provide superior, all position TIG weld quality. Due to low deposition rates, regular TIG is rarely considered for welding fabrication parts > 4mm. In contrast TIP TIG is suited for any all position welds from the root pass to the finished welds. Note picture left in which TIP TIG is used for welding vertical up 3/8 (9.6mm) duplex test plates used for large juice containers in ship construction. Note no smoke, and of course no weld repairs were required. TIP TIG AND INCREASED ALL POSITION TIG WELD PRODUCTIVITY. We are now establishing TIP TIG manual weld procedures that depending on the component / pipe / vessel / plate wall thickness will in contrast to traditional TIG welds typically produce an hourly, all position weld deposition increase of 100 to 400%. When welding vertical up or overhead welds, TIP TIG can compete with the weld times attained with flux cored and pulsed MIG and produce far superior weld quality with less weld rework, less distortion and with minimum weld smoke as seen in the photo on the left. TIP TIG, "REDUCED VEE - J EDGE PREPS REQUIRING LESS WELD AND LESS HEAT. With TIP TIG you get the greatest all position side wall weld fusion potential from the higher energy (increased TIP TIG weld amps) and the agitated weld pool. TIP TIG will provide further weld cost reductions on many applications by enabling a dramatic decrease in traditional pipe and plate J groove and Vee groove weld joints. Also on many alloy welds you may be able to use less preheat and have less concern for interpass temperatures. TIP TIG RESULTS IN LESS TIG WIRE AND LESS GAS COSTS. With TIP TIG you will utilize lower cost MIG wire spools or reels. In contrast to traditional TIG which uses more costly short wire lengths with wasted wire ends, with TIP TIG you can expect approx. a 20% reduction with weld wire costs. Also as most TIP TIG welds are made at much faster weld travel rates than regular TIG welds you typically will require 20 to 50% less argon weld gas. TIP TIG SOME ROOT WELDS AND VESSEL / PLATE ROOT WELDS WITHOUT THE GAS PURGE. On many ROOT plate, tank or vessel weld applications that require a gas purge, the TIP TIG process may enable manual controlled open root "two sided welds". We can demonstrate this two side root cost saving technique to your weld personnel. The two sided, two operator TIP TIG open root weld technique can on specific applications ensure "first time sound quality. The TIP TIG open root welds will be made without back gouging, without back up bars and without gas purge costs. North America: We are pleased to report that Welding Services (Aquilex) - Westinghouse - Exon Research - Bechtel and TI Fab one of the biggest Titanium fabricators in the USA have now ordered TIP TIG units. TIP TIG Sales / Technical Contacts. North - S. America or Australia contact Ed Craig / Tom O'Malley / Nick Corso. ed@tiptigusa.com. tom@tiptigusa.com. nick@tiptigusa.com 10 FUNDAMENTAL REASONS TO VISIT OUR NEW JERSEY FACILITY AND VIEW THE TIP TIG PROCESS. [1] Most TIP TIG welds will typically be made 100 to 400% faster than regular TIG. Smaller vee preps and lower consumable costs will also dramatically reduce the weld costs. [2] TIP TIG always provides superior weld quality than regular TIG, STICK, PULSED MIG, RMD - CMT OR GAS SHIELDED FLUX CORED. [3] In contrast to regular TIG, the faster, TIP TIG electrode negative weld speeds will produce; [] The smallest weld HAZ. [] Superior Mechanicals. [] Superior Corrosion properties. [] Less Oxidation for cleaner welds. [] Superior fusion any applications. [] Less Distortion. [] Lower Stresses. [] Less concern for Cracks. [] Less concern for internal weld Pores and Inclusions. [] Always the lowest Fumes. [4] With all position pipe welds, the TIP TIG process provides superior control and once learnt is easier to use than regular TIG. [5] No other manual or automated weld process can provide the weld quality and the "process controls" that can be applied to the TIP TIG process. [6] On many TIP TIG tank, large vessel, plate weld applications you may be able to use the "two sided" TIP TIG process on open root welds. With the two side root technique you may not have to fill the vessel with purge gas, provide root backing or do extensive root grinding or back gouging. [7] As the TIP TIG welds will be the cleanest you have ever produced, your weld shop can cut back on the purchase of grinding wheels, stainless brushes etc. [8] Numerous TIP TIG weld / part mechanical / corrosion properties benefits are attained on all alloys. [9] TIP TIG produces less weld fumes than any other process. With the OSHA stainless (chrome) fume requirements you will not need exhaust equipment for most stainless, nickel and high alloy welds. [10] In contrast to regular TIG, the higher weld travel rates attained from TIP TIG will enable less weld distortion.

 

WITH TIP TIG THERE ARE NUMEROUS WELD QUALITY AND PART BENEFITS. [] With TIP TIG the weld shop will have the ability to apply the most effective manual Best Weld Practices and Process Controls achieving greater conformance to weld procedure requirements. [] TIP TIG REQUIRES LESS SKILLS THAN MIG OR REGULAR TIG FOR ALL POSITION WELDS. [] For code quality welds, the TIP TIG welder can use a single weld process for any weld, any alloy and any weld position. [] THE TIP TIG WELDER WILL USE SIMPLE WELD PROCEDURES. [] The TIP TIG welds will provide the lowest weld heat which will provide numerous weld benefits for all heat sensitive weld alloys. [] TIP TIG ENABLES LOWER WELD DISTORTION, THE LOWEST WELD OXIDATION, SUPERIOR MECHANICAL / CORROSION PROPERTIES AND LESS CONCERNS WITH SLUGGISH ALLOYS.

While many weld companies would be happy with a 10 - 20% increase in TIG weld productivity, with TIP TIG we can show you better weld quality with a conservative productivity increase in the range of 100 to 300%.

Note weld cleanliness, the extremely small HAZ and no spatter.

IN CONTRAST TO REGULAR TIG, THE TIP TIG PROCESS CAN BE USED FOR SMALL OR LARGE WELD APPLICATIONS WHICH AT YOUR FACILITY AT THIS TIME MAY BE DONE WITH MULTI-PROCESSES. WELD SHOPS TYPICALLY HAVE MANY QUESTIONS ON WELD PROCESS SELECTION: [] Which process should we use for the pipe root? [] Which process is best for the pipe fill passes? [] Which process for those vert up / over head plate welds? [] Which process will provide the best weld quality, lowest weld rework and best side wall fusion? [] Which process enables best control of ferrite levels? [] Which process produces the least distortion? [] Which process provides the best metallurgical properties? [] Which process is best for sluggish alloys? [] Which process is best for the weld repairs? [] Which process provides the cleanest welds? [] Which process will enable the least weld pre-heat? [] Which process can use the smallest vee prep? [] Which process provides the lowest weld dilution for clad welds? IT'S A BASIC FACT THAT CAN BE PROVEN WITH WITH A QUICK TIP TIG DEMONSTRATION ON ANY PARTS YOU WANT TO SUBMIT. IF YOU HAVE TO PRODUCE ALL POSITION CODE OR HIGH QUALITY WELDS AND WANT TO CONSISTENTLY PRODUCE OPTIMUM WELD - CLADD RESULTS WITHOUT REWORK OR LIABILITY CONCERNS, GIVE CONSISDERATION TO THE TIP TIG PROCESS.

WELDING STAINLESS, DUPLEX, INVAR OR ANY ALLOYS PLATES, TANKS
OR LARGE VESSELS THAT REQUIRE ROOT GAS PROTECTION?

Only one weld process can produce this untouched weld quality

FEB 2011: AN ARTICLE EXCERT FROM THE MILLER ELECTRIC WEBSITE. THE ALLOY PIPE WELDS UNDER DISCUSSION WERE CARRIED OUT WITH A MILLER DYNASTY 350: "An Introduction to Alloy Pipe: Techniques for TIG Welding Success" The Miller article states that with alloy pipe TIG welds you should "slow down, you move too fast". At TIP TIG we would tell you to speed up on those sluggish alloy welds as we have no "sluggish" weld concerns. The Miller article states that while alloying elements such as nickel, chromium, molybdenum, copper and cobalt add greater mechanical properties to carbon steel pipes, they also makes the pipes more difficult to weld. The article focuses on the GTAW pipe weld techniques required from welder’s perspective, so that he or she can make the transition from GTAW welding carbon steel to GTAW welding alloy metals such as stainless steel, duplex stainless steel, Inconel® (Ni-Cr, Ni-Cr-Mo and Ni-Cr-Co-Mo alloys), Monel® (Ni-Cu and Cu-Ni alloys) and pipe from related alloys. While each alloy has its own specific considerations, enough similarities exist when TIG welding. The Miller Article: Alloy metals have a lower thermal conductivity than steel, and the molten alloy weld puddle has a lower viscosity. Because the TIG weld puddle is not as fluid, it does not does not “wet” as readily. The welder familiar with mild steel must physically and psychologically make adjustments. Key among them, slow down! Slow down for stainless steels, slow down more for duplex steels and slow down even more for nickel alloys. Traveling to quickly can lead to problems like cold lap. Do not attempt to compensate for a sluggish puddle by increasing weld current. Using more current than the weld procedure dictates will vaporize (“burn out”) the alloying elements, leading to corrosion and reduced service life. For this reason, use a low to moderate heat input, visually inspect all welds for indications of excess heat input, typically a color change. This step is critical. THE TIP TIG RESOLUTIONS FOR WELDING SLUGGISH ALLOYS: The Miller TIG equipment is frequently the TIP TIG power source of choice and the article is correct in recommending that when regular TIG welding with any TIG power source, slowing down can be beneficial with sluggish alloys. However weld decision makers need to be aware that when you take a TIG power source like the Miller Dynasty 350 which cannot alone overcome the weld issues that occur with sluggish alloys, and you then add the TIP TIG process to that power source, you will find the concerns for sluggish alloys and the rules for sluggish alloys dramatically change. When you add TIP TIG weld equipment to any TIG power source, you will not be concerned about the differences between carbon steels and alloy steels, or the consumable or base alloy influence on a TIG weld's viscosity, (wetting) or weld solidification. When welding alloys with TIP TIG, the welds will have additional weld current from the higher wire feed rates and improved weld fluidity from the smaller TIP TIG wire diameters. Also the TIP TIG weld pool will be agitated. These two factors eliminate the traditional sluggish weld fusion and porosity concerns with all alloy weld applications. The faster TIP TIG weld speeds with any alloy welds also dramatically lowers the weld joules delivered, this results in four prime benefits that should please any weld decision maker. [1] TIP TIG is a process which overcomes the regular TIG - Hot Wire TIG and Pulsed MIG, sluggish weld solidification issues with all alloy welds, [2] TIP TIG enables the lowest possible weld heat input for any weld application. [3] TIP TIG enables the lowest weld oxidation potential and therefore the cleanest possible welds. [4] TIP TIG lowers regular TIG weld labor costs in the range of 50 to 400%

 

 

Watch what is wrong with the regular TIG process. THE LOW DEPOSITION, TIG ONE SECOND DIP.

Dip that oversize TIG wire in the weld and quickly pull it out. The Achilles heel of regular, manual TIG, no matter what the alloy and no matter what the weld you will usually require the dip skills and end up with frustrating slow weld speeds typically in the range of 2 - 10 inch/min. With TIP TIG you will make superior quality welds and typically increase the deposition in the range of 100 - 400%.

 

THE COMMON ONE SECOND REGULAR "TIG DIP" & THE RESULTING SLOW TIG WELD SPEEDS: Take an average TIG welder welding a 1/8 (3 mm) steel or stainless fillet weld. The welder would perhaps take a 3/32 (2.4mm) weld wire and approx. once a second dip that wire tip into the weld. In that second, the welder will add between 2 - 3 mm (1/8) to the fillet weld length . At the end of a minute, the welder completes that 3 mm fillet with a weld wire length of approx. 6 to 10 inch (15 - 25 cm). A regular TIG welder would make this weld at a typical weld speed of 6 to 10 inch/min. In contrast the TIP TIG manual welder would make the same 3 mm fillet weld at weld speeds between 30 to 48 inch/min. When larger fillet welds are required, the regular TIG welder will have to aggressively weave that fillet weld and while dipping the TIG wire on average 60 times per minute, the TIG welder still only adds an equivalent value of what was added to that 3 mm fillet. For that larger fillet weld, the TIG weld speeds will be dramatically reduced and the regular manual TIG welder will be welding at typical weld speeds of 2 to 4 inch/min, in contrast the TIP TIG welder will typically make those welds at speeds of 8 to 15 inch/min.

A PICTURE IS WORTH A THOUSAND WORDS. TAKE A
LOOK AT THIS TIP TIG 1/4 (6mm) HORIZONTAL FILLET WELD.

TIP TIG MANUAL FILLET WELD. ALLOY 400.

Examine the above weld energy, the weld consistency,
the smallest possible HAZ, the weld cleanliness and weld continuity.

 

FOR THOSE LOOKING AT "PULSED MIG" CONSIDER; ON MANY PULSED MIG ALL POSITION WELD APPLICATIONS > 5mm, YOU CAN ANTICIPATE EXCESS WELD HEAT IN THE PARTS, OCCASIONAL LACK OF WELD FUSION, SPATTER, WELD POROSITY & OXIDE INCLUSIONS AND POOR SUITABILTY FOR ALL POSITION WELDS. In the last three decades, many of the major global weld equipment manufactures focused on the installation of "electronic components into their MIG weld equipment". The weld reality of pulsed MIG is the real world practical steels and alloy steels weld benefits attained from the pulsed electronics are often only in the mind of a salesman. After personally evaluating pulsed MIG equipment for approx. 25 years, from my perspective I believe that the REP pulsed MIG process is not capable of providing optimum, consistent, all position weld fusion on applications over > 5 mm. The pulsed MIG weld issues become more of a concern if the alloys welded are considered "sluggish". [] In contrast to REP pulsed MIG in which most of the weld heat is in the arc and weld wire, on the same welds attained by the higher temperature more focused arc, the TIP TIG weld heat has greater dissipation into the base metals preheating the weld fusion area increasing side wall weld fusion potential. [] The fluctuating pulsed MIG peak to back ground parameters provide an inconsistent arc plasma with lower arc temperatures than that attained with TIP TIG. [] For steels and alloy steels, Pulsed MIG uses "reactive gas mixes" which increase oxide formation which increases weld porosity / inclusion potential. TIP TIG only requires one gas "inert argon" and the EN - TIP TIG welds should always be cleaner. [] With the Pulsed MIG process you will have "wire stick out (WSO) changes" during the weld. The common WSO variations can typically provide 10 to 25% changes to the pulsed MIG weld parameters effecting the weld quality consistency. WSO is not an issue with TIP TIG. [] In contrast to TIP TIG, manual pulsed MIG lacks the ability with manual welds to control the weld starts / stops and tie-ins data. [] In contrast to TIP TIG, pulsed MIG requires much higher voltages than TIP TIG and the higher voltages combined with the REP imparts much more heat in the weld's HAZ.     Feb. 19 2010: E-Mail To Ed at www.weldreality.com. Subject: MILLER PIPE PRO AND PIPE WELDS: Ed. Reference our recent experience with the Miller MIG Pipe Pro utilized for MIG for pipe root / fill passes. PIPE ROOT WELDS & RMD: In controlled welding conditions using the Miller "RMD short circuit process" for the root we would experience lack of fusion at the side of the root bead on P1 group 1 Carbon Steel pipes.  The root weld defects did not show up in radiographs but were obvious in the radius side bends. On the pipe ID the root bead was through, but narrow in spots. Although the weld defects were corrected at the PQT they came back with a change of MIG wire from a different wire manufacturer. PIPE FILL PASSES & PULSED MIG: Mechanical testing of the pipe fill passes was then carried out for the same pipes with the Miller Pulsed MIG mode available on the Pipe Pro power source. We decided on these pipes not to use the RMD process for the root passes and instead used TIG for the root pass and it was notable that the TIG side bend tests had zero defects. For the fill passes we used the Miller pulsed MIG process. With this process  we had four coupons  with lack of fusion defects between first fill pass and the root bead. Ed the bottom line is we don't have a lot of confidence in either the Miller RMD process for the roots or the Miller pulsed MIG or FCAW processes for the 5G fill passes. The Miller sales rep claimed an apprentice welder can make pipe welds with this equipment with two days training. As you well know Ed, it's not making the pipe welds that is the concern, it's having the welders first time pass the weld NDT requirements so we can avoid costly weld rework. It looks like we are heading back to TIG for both the root and fill passes, which brings up my interest in TIP TIG. Regards TW: Ed developed the world's largest web program on MIG - Flux Cored Best Weld Practices and Weld Process Controls, its called www.weldreality.com.

WELDING STEELS AND ALLOY STEELS. TIP TIG IN CONTRAST TO PULSED MIG:

Process	Volts	Opt Weld Transfer and AMP RANGE	Control of Arc Starts Arc Stops	Reactive Gas or special mixes?	Wire Stick out influence	Roots and all position fill pass capability	Heat sensitive alloys
REP PULSED MIG	23 28	100 - 300	No	Required influence oxide reaction.	Negative	Not Capable	High heat
EN TIP TIG	12 16	100 - 400	Yes	Not required. Lowest oxidation.	No concern	First Choice	Lowest heat

 

IN CONTRAST TO REGULAR TIG, THE TIP TIG PROCESS WHEN WELDING LARGE DIAMETER OR THICK WALL PIPE WILL TYPICALLY DELIVER 200 TO 350% MORE WELD FOR THE PIPE FILL PASSES. THANKS TO THE FASTER TIG WELD TRAVEL RATES AND THE EN POLARITY, THE TIP TIG WELD HEAT INPUT WILL ALWAYS BE THE LOWEST.

STEELS AND ALLOY WELDS. MORE DIFFERENCES BETWEEN TIP TIG & PULSED MIG: [] TIP TIG in contrast to pulsed MIG enables much lower weld volts which combined with EN and moderate TIP TIG weld speeds can result in the lowest possible weld joules providing extensive weld / part mechanical and corrosion benefits along with lower weld distortion. [] TIP TIG in contrast to pulsed MIG enables the widest welding amp range with low voltage which dramatically increasing the part thickness and "all position" weld application potential. [] TIP TIG in contrast to pulsed MIG enables amp ramp up / down data that provides superior quality on any weld starts / stops and weld tie ins. [] TIP TIG in contrast to pulsed MIG is not influenced by the common MIG wire stick out changes. [] TIP TIG in contrast to pulsed MIG always provides superior weld fusion and superior weld controls with less internal pore and inclusion weld defects. [] TIP TIG in contrast to pulsed MIG will always provide superior all position welds. [] TIP TIG in contrast to pulsed MIG will produce no weld spatter. [] TIP TIG in contrast to pulsed MIG has no concern for sluggish alloys. [] TIP TIG in contrast to pulsed MIG can reduce pre-heat / interpass requirements. Also if you clad or hard face TIP TIG will produce less cracks. [] TIP TIG in contrast to pulsed MIG uses straight argon and has the lowest possible weld oxidation potential producing cleaner welds on any parts. [] TIP TIG welds in contrast to pulsed MIG will rarely require grinding or brushing. [] TIP TIG in contrast to pulsed MIG on any 5G pipe application can weld the root with better control than regular TIG, STT, and RMD and TIP TIG will always provide superior all position fill pass weld fusion producing pipe welds with the lowest possible internal pore defects, welds with superior side wall fusion, welds with the lowest oxidation and welds that produce the smallest HAZ. [] TIP TIG will produce less weld smoke than any MIG process.

TIP TIG the worlds best process for
resolving Weld Distortion concerns.

If you weld stainless or alloy components and maintaining dimensional tolerances is important to your weld application, take note of the following. When you weld with TIP TIG at MIG weld speeds, you attain the benefits of the lowest possible weld joules which when combined with electrode negative weld heat disbursement into the base metal, you will end up with the highest possible weld quality with the lowest possible weld distortion.

E71T-1 Gas Shielded Flux Cored Wires.

No matter what the flux cored consumable manufactures claims, you know
with the flux cored process there can never be manual weld quality guarantees.

WELD SHOPS GRINDING - CLEANING AND WASTE:


Its' a shame in those weld shops that weld stainless, inconel or other costly alloys to
watch the welders get paid to produce the costly welds and then watch
the same welders pick up a grinder and remove much of the weld.



WITH TIP TIG IT'S RARE TO REQUIRE A GRINDER,
A WIRE BRUSH OR AN EXHAUST UNIT.

WELDING SMALL FILLET WELDS AND LONG WELD LENGTHS: Welding controlled long length, consistent optimum quality, small 2.5 - 4 mm fillet welds has for decades been a challenge for the global weld industry. MIG spray frequently deposits too much weld metal and MIG short circuit often does not provide sufficient weld energy. Also the weld heat from the MIG REP process, often provides weld distortion issues. Regular TIG will require too many weld start / stops and the slow TIG process will also provide weld heat distortion concerns.

In contrast to regular TIG, the TIP TIG welds when used with welds from 3 mm to any size will produce many benefits
[a] welds with the lowest oxidation,
[b] welds the lowest distortion,
[c] welds with the least weld pores,
[d] welds with the best side wall fusion,
[e] welds with less arc start / stops,
[f] welds with the smallest heat affected zones,
[g] welds that are typically 200 to 500% faster.

Visit the home section to view a great video on TIP TIG 3 mm manual fillet welds at 45 inch/min weld travel.

THE best process for pipe weld roots is TIP TIG.

TIP TIG best process for pipe fill passes.

TIP TIG & BASF HALF PIPE SNAKE WELDS

As the TIP TIG welder no longer has to feed a weld wire with one hand or worry about a leg cramp with that foot control, the TIP TIG welder can focus solely on the weld and use one hand to stabilize his body or put two hands on the torch for extra torch control. Remember with TIP TIG, the constant fed wire is always fed into the arc sweet spot.

With the the half pipe snake weld application indicated in the photos, the weld shop did not like the inconsistent weld quality, the weld distortion, the weld fumes and weld spatter attained from the Pulsed MIG process. These stainless 316L tanks and similar tanks are typically used in chemical, pharmacy and food industry. This vessel was for BASF Germany. BASF demands the highest possible weld quality. This project manually welded with traditional TIG and a 3/32 wire would have a weld deposition rate average of approx. 0.3 lb/hr with weld speeds typically in the range of 3 - 4 inch/min with more start /stops than you could count. In contrast, the manual TIP TIG weld deposition rates on this application enable manual weld speeds for the 3/16 fillets of 12 - 15 inch/min. These manual TIP TIG weld speeds and the small TIP TIG HAZ ensured minimum distortion. BASF. QA and weld personnel were amazed at the defect free weld quality. Of course with no weld spatter and smoke issues, and at the weld completion the weld surface cleaning was dramatically reduced.

[1] MORE TIP TIG WELD BENEFITS: WELDER COMFORT AND WELD QUALITY:
Most weld personnel that have a good attitude and can embrace change will need a few hours to get used to the TIP TIG torch, the weld requirements and TIP TIG techniques. With the light weight TIP TIG torch, welders can use one or two hands on the torch and not having a foot control for most applications is a big plus for many. It's important for management to remember that when welding pipes, aircraft parts, turbine vanes or welds on a nuclear submarine, the more comfortable the welder and the less skills required, the greater the potential for optimum, consistent weld quality and productivity.

[2] TIP TIG WELD BENEFITS: ALWAYS SUPERIOR MANUAL & AUTOMATED WELD QUALITY:
In the last decade, the two growth weld processes for all position pipe welds has been pulsed MIG and Flux Cored. Both of these processes when used in manual pipe applications will irrespective of the manual welders skills produce common weld defects as discussed in this section and in the Pulsed MIG / Flux Cored sections in my weldreality.com site. The Pulsed MIG and flux cored weld processes are not suited for open root welds and the defects that will be derived from both these processes on code applications will typically require additional NDT costs and costly weld repairs. In contrast a ten minute demo with the TIP TIG process would reveal it should always deliver manual or mechanized weld quality that's superior to traditional TIG - Pulsed MIG - Fronius CMT - Miller RMD - Lincoln STT - MIG Spray - Short Circuit - Flux Cored.

[3] TIP TIG WELD BENEFITS: MUCH LOWER WELD LABOR COSTS:
If you are involved with weld costs, be aware that every time you have two or three welders using the conventional TIG or SMAW weld processes, one welder using the TIP TIG process will typically produce similar production and always produce superior weld quality.

In this time of difficulty in finding skilled welders, weld shops should be aware of the value of process that requires less weld personnel, is easier to teach and always provides the highest possible all position weld quality.

[4] TIP TIG WELD BENEFITS: LOWEST WELD FUMES:
OSHA 2010 has new strict safety regulations for welders working with high chrome alloys, (chrome fumes - particles concerns). On most stainless weld applications, irrespective of the alloys used the TIP TIG process will typically ally not require exhaust equipment. Thanks to the increased TIP TIG weld speeds and electrode negative, no other weld process including regular TIG will provide less weld fumes than TIP TIG.

[5] TIP TIG WELD BENEFITS: SIMPLE WELD PROCEDURES:
That new nuclear or coal fired power plant, or the new oil rig if welded by the TIP TIG process could be built with a manual and automated weld quality and productivity never before attained. No matter how difficult the welds or how complex the welding alloys are, typically three to four common TIP TIG wire feed - amp weld settings would apply for any weld application, any weld position and any steel or alloy.

2010. CROTIA SHIP YARD TIP TIG WELDS LEAN DUPLEX TANKS

24 TIP TIG units were used to weld these Lean Duplex Tanks 1/4 - 3/8. (6-9mm) The ships contaIners were 12 - 17 meters wide by 20 meters in height. The ship yard attained a weld quality and production never before attained with regular TIG or pulsed MIG on duplex pipe, plate and vessels.

 

 

Interested in weld automation? Visit TIP TIG weld automation.

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


Interested in weld automation?
Visit TIP TIG weld automation.

 

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 AND MANY MORE.

 

It takes less than a 30 minute demonstrations to show that the TIP TIG process will
produce superior all position automated clad and weld quality than the regular
Hot Wire TIG, Pulsed MIG or the Short Circuit process. Live video.


Click on the Evolution of TIG icon if you want a TIP TIG brochure.




Left: Traditional TIG requiring two hands, a foot control, high skills, low amps.
The process delivers inconsistent wire feed, many start / stops and excess weld heat.

In contrast to TIG with TIP TIG the welder uses one hand and is more relaxed. TIP TIG delivers higher weld energy, consistent wire feed rates and welds much faster. Note: For TIP TIG pipe benefits visit the "pipe section".

If you use regular TIG, Pulsed MIG or Flux Cored high quality
weld applications, its time you looked at TIP TIG.

TIP TIG Inconel Screw Weld:
Welding Wire: Inconel-625.
Weld wire size 0.045 (1.2mm).
Shield Gas Argon.

On this application the TIP TIG amp range was 300 - 380A. Weld deposition rate for an application like was 400% greater than regular TIG.

Remarks: For those of you that use costly helium - argon or argon - hydrogen mixes, these mixes are rarely required with TIP TIG as this process enables an agitated weld pool with higher current that results, benefits that provide more weld energy.

With TIP TIG welds, the highest first time weld quality should be consistently attained. Thanks to the TIP TIG high weld energy and puddle agitation, the welds were 100% free of pores and defects. Note the one hand Inconel welds made with ease.

CLADDING OR HARD FACING SPECIAL ALLOYS LIKE STELITE 1 - 6 WITH TIP TIG
AND YOU WILL SEE WELD BENEFITS LIKE SUPERIOR WELD QUALITY, LOWER DISTORTION
AND DRAMATIC REDUCTIONS IN PRE-HEAT AND INTERPASS TEMPERATURES.

Considering the SMAW Process? Every weld shop knows the weld issues generated with the stick weld process. And every weld supervisor knows that the only way to attain optimum, first time weld quality with the stick process is to provide the welder with a good grinder and then say a few prayers.





If all position, code weld quality, optimum weld cleanliness, optimum weld uniformity welds with the lowest weld heat and no fume concerns are factors that will benefit your weld shop, than give consideration to the TIP TIG process.

QA WELD SHOP PERSONNEL. THE MANUAL OR AUTOMATED TIP TIG PROCESS SHOULD REDUCE THE REQUIRED WELD PROCEDURES. TIP TIG WILL ALSO SIMPLIFY THE WELD PROCEDURES, THE WELD QUALIFICATION AND CREATE OPTIMUM WELDER CONFORMANCE.

For the typical weld shop, think about the variety of the weld equipment and weld consumable options. Welders will daily use regular TIG - SMAW - MIG - STT - RMD - Flux Cored and Metal Cored and too often many welders who lack process control expertise will "play around" with their weld controls.

Considering Pulsed MIG for your weld procedures? Be aware that those complex Pulsed MIG weld procedures should change when that different Pulsed MIG power source is used, or new, ever evolving Pulsed MIG power source are introduced to the weld shop bringing changes to the weld essential variables.

KIS - KIS - KIS: As someone who has spent 40 plus ears simplifying and optimizing MIG and flux cored weld quality and productivity and has developed hundreds of weld procedures in 12 countries, I know the importance of keeping things simple in the weld shop.

When weld shops have to start thinking about MIG Short Circuit - MIG Spray - MIG Globular - MIG Pulsed - MIG STT - MIG RMD - MIG CMT - Gas Shielded Flux Cored and the traditional TIG and SMAW processes and numerous weld consumables, you know weld issues will always be around the corner and life in the weld shop is not going to be simple. In contrast, when using TIP TIG, you will have one weld gas argon and two or four simple wire feed and amp weld settings and that's all any weld shop will require to produce cost effective, defect free manual or automated welds on any alloy, any weld position and any application.

 

TIP TIG. Smoke Free. Spatter Free. Defect Free Welds.
Simple to use at MIG Deposition rates.

TIP TIG, the more complex the alloy to be welded, the better the weld results.

TIP TIG SOLUTIONS TO STAINLESS EXHAUSTS. MINOR MIG SPATTER CONCERNS. An automotive supplier used Fronius MIG - CMT for welding stainless steel exhaust systems. On the exhausts the low spatter CMT process produced "small amounts of weld spatter" and the company could not deliver the parts without grinding hundreds of parts each shift. The automotive company looked for a solution and switched to TIP TIG. The TIP TIG equipment slightly increased the weld productivity and the TIP TIG welds had zero defects on parts that required no cleaning.

 

MANUAL TIP TIG WITH AUTOMATED WELD QUALITY.
SMALL CRITICAL WELDS FOR TESCOM.

 

TIP TIG Welds: TESCOM Material: 1.4404 Tube: Diameter 20 mm x 5.5mm wall thickness. Filler material: 1.4430. This manual TIP TIG weld required 3 passes for the 5.5 mm VEE weld prep. In contrast to traditional TIG, the manual TIP TIG welds were more uniform and for those that care about weld costs, the TIP TIG weld time reduction was 100%. Note the manual weld continuity and the small weld heat affected zone from the 3 TIP TIG weld passes.

 

TIP TIG Welds Hastelloy C22
Weld Wire: Hastelloy C22
Weld Position: 2G.
Remarks: Highest quality, lowest oxidation,
great continuity, full penetration defect free welds.

Note the TIP TIG Hastelloy C22 weld continuity, the "untouched" welds with lack of oxidation and great weld cleanliness and take note of that small weld HAZ which will improve metallurgical properties and minimize distortion. The TIP TIG manual weld speed was 300 - 400% faster than traditional TIG. It's not possible to duplicate this TIP TIG weld quality with traditional manual TIG, flux cored or the pulsed MIG process.

TIG 1/4 (6mm) STAINLESS FILLET.

FIRST TIME USER WITH THE TIP TIG WELDING STAINLESS: WELDING 1/4 (6 mm) OUTSIDE CORNER WELD. NOTE THE TIP TIG PROCESS IS WELDING FASTER THAN THE REGULAR TIG PROCESS WELDING THE 1/8 (3mm) FILLET IN THE ABOVE LEFT VIDEO. On most stainless welds, TIP TIG will produce superior weld quality than the regular TIG process. If you are thinking about pulsed MIG, with TIP TIG again you have better weld quality, the lowest possible weld heat input, the lowest fumes and of course welds without spatter.

Note if a regular TIG welder was doing this 1/4 (6mm) fillet weld,
they would typically do 2 - 3 weld passes and use an aggressive weave.

 

TIP TIG will provide extensive weld benefits for the Chemical, Oil, Ship Building, Beverage and Food Processing Equip industries.

Tanks, Pressure Vessels, Plate Fabricators. Duplex - Invar -
Stainless - Inconels - All Corrosion Resistant Alloys.

WITH TIP TIG, WELDERS CAN PERFORM TWO SIDED TIP TIG OPEN ROOT WELDS ELIMINATING TANK OR VESSEL GAS PURGING AND BACK GOUGING ON ALLOYS THAT REQUIRE ROOT BACK SIDE GAS PROTECTION.

When you are dealing with code quality open root welds on large projects, weld rework, NDT costs, weld grinding, gouging weld cleaning and weld skills inconsistency, all have an impact on your companies profits, the TIP TIG process can address those issues.

Note: As with all our TIP TIG welds, examine the minimum HAZ on the duplex welds and note the remarkable weld cleanliness and the weld fluidity. You know these duplex welds will pass any weld mechanical
requirements and not fail any weld NDT tests.

WHY STRUGGLE WITH FLUX CORED OR PULSED MIG WHEN YOU
CAN PRODUCE MANUAL TIP TIG DUPLEX OR STAINLESS
OVERHEAD, UNTOUCHED FILLET WELDS THAT LOOK LIKE THIS?

TIP TIG single pass "over head weld" on 5/8 Duplex:


Difficult sluggish alloys and difficult weld positions are no longer a
concern with TIP TIG. This lean duplex, TIP TIG weld is made with DX2101 wire.
Note the large weld control, lack of oxidation, weld cleanliness and weld continuity.



ALL POSITION WELDS. TANKS - PRESSURE VESSELS - PLATE

Do your untouched "vertical up" stainless or duplex welds look like this
manual TIP TIG weld and would your welds be free of weld defects?

This vertical up TIP TIG duplex weld was made
by a a first time user of the TIP TIG process.
Note weld color and small HAZ.

 

On a stainless or duplex vessel there is no other manual
process that will deliver the quality that TIP TIG delivered.



Note the portability of the TIP TIG wire feeders.

A REMINDER OF TYICAL WELD ADVANTAGES FROM TIP TIG WELDS ON ALLOY STEELS.

[] TIG TIP welds with higher deposition rates than traditional TIG, so the TIP TIG weld gas costs will be dramatically reduced by 50 - 200 %.

[] TIP TIG uses standard 30 LB MIG wire spools which in contrast to pre-cut TIG wire will dramatically reduce weld wire costs.

[] With one handed TIP TIG requirements and the lack of a foot control, TIP TIG reduces both physical and skill requirements for the TIG welder.

[] TIP welds typically from 50 to 500% faster than all traditional manual TIG welds.

[] The faster weld speeds from TIP TIG can in contrast to any process provide lower weld heat input into base metal. TIP TIG therefore produces the smallest possible HAZ, the lowest weld distortion and welds with the lowest weld stresses.

[] In contrast to traditional "automated" Hot Wire TIG welds, TIP TIG provides superior weld quality and the process is much less sensitive to variables that can impact automated TIG welds.

[] In contrast to any weld process, TIP TIG welds will always provide all position, superior weld fusion with less weld porosity.

[] TIP TIG provides the opportunity to reduce vee and "J" groove angles dramatically reducing labor and consumable costs.

[] In contrast to pulsed MIG, flux cored or regular TIG, the TIP TIG process provides superior weld quality for any all position weld.

[] Of all the available manual or automated weld processes TIP TIG produces the lowest weld fumes and as TIP TIG welds require no grinding there is less concern for airborne grinding particulates.

[] In contrast to pulsed MIG. SMAW and flux cored, TIP TIG dramatically reduces arc start / stop weld defects, which are common with pulsed MIG, flux cored and traditional TIG.

[] TIP TIG brazing can be as fast as MIG brazing, but without the spatter and superior braze control.

[] With any clad welds TIP TIG will always provide superior weld quality and does not require costly Arc Voltage Controls typically associated with automated TIG applications.

[] TIP TIG needs minimal parameter changes for complex welds which simplifies the production of PQR's and weld procedures.

 

Over 20 years ago I had to lead a project repairing failed welds on USA. Textron Sting Ray tanks in Thailand,
(Ed in middle). I wish I had TIP TIG to do the weld repairs on the heat sensitive 278K Tensile Armor plate.

The defense industry welds many complex alloys and they will appreciate
TIP TIG as this process enables the highest possible weld quality with
increased weld production and less heat than regular manual TIG.

OMPANIES WHO HAVE ATTENDED THE TIP TIG WORK SHOPS.

AREVEA - EXON - WESTINGHOUSE - WELDING SERVICES - KELLY CONSTRUCTION - TI-FAB
DELTA AIRLINES - ARMISTEAD MECHANICAL - UNION METAL - MID STATE CONTRACTING -
TRIUMPH FABRICATIONS - SIEMENS - ROLLS ROYCE - ENERFAB - DIAMOND POWER -
BODY COTE - SPACEX - NORTHROP GRUMMAN AND MANY MORE.

On these 409 thin gage parts, Pulsed MIG could never attain the weld quality of TIP TIG.


Left: Untouched 100% penetration TIP TIG tube weld made at 30 inch/min.
Right: Customers Pulsed MIG 100% penetration. Apart from the obvious
quality differences, look at the weld heat affect .

 

 

Food Processing or Pharmaceutical welds.

TIP TIG, best sheet metal quality on > 14 gage no smoke, no spatter, lowest weld cleaning, lowest distortion and weld TIG weld speeds in the 15 to 40 inch/min range.

 

TIP TIG 409 16 GAGE SEAM WELDS.	TIP TIG 409 16 GAGE SEAM WELDS
If you compared pulsed MIG with this 409 TIP TIG seam weld you would instantly note the superior weld quality from TIP TIG. While the full penetration Pulsed MIG may have weld fume concerns, weld oxide formation, weld spatter, distortion, undercut and require manual cleaning or weld rework, in contrast the TIP TIG welds would not create these common weld production issues.	The customer wanted to see the quality and ease of use in a production capability for TIP TIG on this seam application. Set up was easy and required about 15 minutes. Simply attach the TIP TIG torch to a low cost auto carriage. The part welded is the first of 3 test pieces provided. At TIP TIG we don't need to "play around to attain optimum weld results. Within a few minutes we were continuously providing parts as shown on the left. With automated TIP TIG seam gage welds like this, you can anticipate the welds would be made between 25 and 35 inch/min. (typical 300 to 500% quicker than manual TIG and compatible with many MIG welds.

TIP TIG. TWO SIDED ROOT WELDS. COULD BE PLATE, TANKS, VESSELS OR PIPE.
Any weld alloy that requires an open root and typically requires a purge to protect the root is an application in which you may want to consider TIP TIG. The above TIP TIG demo is simply a piece of stainless plate with an open root. Imagine this root is part of a 30 foot diameter duplex or stainless tank, how would you approach that root protection?

 

MANY WELDS DON'T HAVE THE WELD QUALITY REQUIREMENTS TO JUSTIFY TIP TIG.
IF YOU ARE INTERESTED IN OPTIMIZING YOUR MIG OR FLUX CORED MANUAL OR
ROBOT WELDS, CONSIDER ED'S WELD PROCESS CONTROL TRAINING RESOURCES.

ED HAS OPTIMIZED "ROBOT / manual WELDS" FOR HUNDREDS OF COMPANIES IN 12 COUNTRIES.
A FEW OF HIS PROJECTS, THE FORD F150 TRUCK FRAMES - VOLVO TRUCK CABS -
CORVETTE FRAMES - HARLEY BIKE FRAMES - NEW VW BEETLE SEATS & THE
ABB ROBOT WELD DATA NECESSARY FOR CATERPILLAR'S WORLD'S LARGEST TRUCK.

If you are interested in Ed's manual and robot MIG and flux cored
weld process control training programs, click here.

 

For a TIP TIG brochure click here.

TIP TIG Sales and Information
call Nick at 856 312 8166.

Interested in TIP TIG weld automation?
Visit TIP TIG weld automation.

On this part, TIP TIG increased the automated TIG wire feed rates by approx.
100% and provided superior welds and mechanicals
while dramatically reducing the weld heat input.


If you are considering a costly AMET, CK or any automated
Hot Wire TIG weld application, consider that TIP TIG will
typically do the same welds often with a 100 - 200% faster wire feed rate


Don't forget to visit the TIP TIG Pipe Weld section or for
TIP TIG Unique "Weld Automation Data" visit here.

FOR THOSE WANTING TO IMPROVE THEIR MIG AND FLUX CORED WELDS: MIG and Flux Cored accounts for > 80% of the welds daily produced. In the majority of global weld shops you will find welders "playing around" with the weld parameters and when weld advice is required the weld shop too frequently turns to a weld salesman. If I was to ask 10 welders one of the fundamental Weld Process Control questions in this weld test, I would get 10 different answers. If I was to ask any responsible weld decision the cost of a common 1/4 (6mm) fillet weld I would get a confused look this is the way it is in 2011 and this is the way it was 40 years ago. With the common lack of MIG - FCAW process controls and lack of best weld practices you create an environment in which its rare when the daily manual and automated weld quality - productivity is optimized. If you manage welding and believe you can do so effectively without weld Process Control knowledge and the implementation of Best Weld Practices, give me a call I would like to find out what planet you are living on.

Before you leave TIP TIG, don't forget to visit the video sections and
also visit www.weldreality the world's largest web site on
MIG - TIG - Flux Cored weld process controls.


Ed's Weld Process Controls and Best Weld
Practices Training Resources

Visit Ed's training materials..

Ed's pulsed MIG patent for improving boiler water wall stainless / inconel clad welds came into effect as of April / 2010. The patent was issued to Welding Services, (Aquilex). Atlanta GA USA.

Ed's MIG clad patent improves the traditional, global, water wall, clad weld quality attained. The pulsed MIG method Ed developed dramatically reduces boiler distortion and stresses, and the amount of stainless or inconel clad material required per-square foot by >28%. It's anticipated that Ed's unique MIG process control approach will become the standard for Aquilex who has been responsible for more than 75% of the boiler water wall clad welds made in North America. Ed's Pulsed MIG clad info available here.

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.