TIP TIG welding is 100 to 500% faster than TIG with superior quality than traditional TIG - Pulsed MIG - FCAW

TIP TIG Welding

 


TIP TIG PIPE - VALVE - VESSEL 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 weld questions call Ed Craig 828 337 2695,




AFTER SIXTY YEARS, THE EVOLUTION OF THE
TIG PROCESS IS CALLED TIP TIG.

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


If you were building a nuclear plant or any project requiring code quality welds, we can demonstrate why no other pipe weld process can provide superior weld quality than the
TIP TIG manual or automated weld process.

 



SINGLE TORCH TIP TIG PIPE ORBITAL:

View untouched, world's best pipe weld quality with the
TIP TIG process and our new automated TIP TIG orbital equipment.

 

[] Any pipe alloy, any pipe diameter,any pipe thickness.

[] 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.

[] Three 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.



Why not put two TIP TIG units on the pipe
and double up the weld benefits?.




WORLD'S BEST PIPE WELD QUALITY WITH THE
TWO TORCH TIP TIG ORBITAL WELD PROCESS.

 

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 PIPE MANUAL.

 
When you reduce the required weld skills for complex welds, the welders are more relaxed and the defects are reduced. When any pipe welder gets their hands on TIP TIG, they instantly know this all position process will provide the best possible quality welds on any pipe root and fill pass welds.

With this root weld the TIP TIG welder knows the root pass is uniform, consistent and it's 50% faster than regular TIG.

With the pipe fill passes, the increased TIP TIG weld energy and unique weld agitation ensure superior pipe weld fusion with welds that will have the lowest possible weld pores and inclusion content. Any company should be pleased to know with the fill passes they should expect 100 - 400% more weld production each hour with the best possible mechanical - corrosion properties.

 


TIP TIG, ONE PROCESS WHICH IS OPTIMUM FOR ALL PIPE WELDS:
With any steel, any thickness, or any alloy pipe weld, in contrast to regular TIG, Hot Wire TIG, FCAW and all MIG STT - RMD - CMT welds transfer modes, TIP TIG will always produces superior pipe root and fill pass weld quality. With TIP TIG, one weld process and three simple weld procedures will cover every possible manual and automated pipe welds and clad application.

TIP TIG, ALWAYS BEST POSSIBLE PIPE WELD PROPERTIES:
As TIP TIG always provides the lowest possible weld heat in the parts welded, with all alloy pipes you should expect the smallest possible HAZ and optimum mechanical and corrosion properties. With TIP TIG you also have a process that provides the widest possible weld joules range.

TIP TIG REDUCES PIPE WELD SKILLS:
In contrast to the regular TIG process, with the TIP TIG process, pipe weld skills are dramatically reduced as the welder does not have too feed a weld wire or use a foot control.

TIP TIG LOWERS PIPE WELD LABOR COSTS:
In contrast to regular TIG, when you use the TIP TIG process for manual and automated pipe welds you shouldl increase your hourly weld production in the range of 100 - 400%.

THE FOLLOWING SECTION SHOWS WHEN WELDING CODE QUALITY PIPE AND PRESSURE VESSELS, WHY THE REGULAR MANUAL TIG, THE AUTOMATED HOT WIRE TIG, FLUX CORED, PULSED MIG, RMD AND STT PROCESSES CANNOT COMPETE WITH PATENTED THE TIP TIG PROCESS.

 



This is the way the majority of rotated pipes should be welded.

 
TIP TIG AND THE TIP TIG PIPE OSSCILLATOR.

No spatter. No slag. No porosity. No lack of fusion. No concerns for sluggish alloys. No fume issues. Always 200 - 400% faster than regular TIG. One process for the root and fill and same process for manual all position pipe welds. Note the quality of the untouched finished weld, it also could be a clad pass.




The tooth brush and manual TIP TIG welds
on Inconel Pipe subject to 100% x-rays :

There were four remarkable achievments with these Inconel, 18 inch diameter, one inch wall, manual TIP TIG pipe welds. These welds were 100% X-Ray to ASME specictions.

[1] From the pipe root to the cap pass, the only tool the welder used to clean the multipass welds was a worn stainless brush not much larger than a tooth brush (brush in photo). ,

[3] The all position welds were carried out 300% faster than the regular TIG or SMAW process.

[3] As with most TIP TIG pipe welds the 100% X-Ray these weld joints attained zero percent weld rework.

[4] The lowest possible weld fumes were produced and no fume exhaust equipment was required.

 

 



PIPE WELD PROCESS CONTROL BENEFITS
FROM THE TIP TIG PROCESS:

When manual welding pipe in any weld position, in contrast to the regular TIG process, the semi automatic or the automatic TIP TIG process offers many weld process control benefits.

[] TIP TIG enables a controlled, consistent TIG wire feed rate which drives consistent, manual weld speeds with reduced weld arc start / stops.

[] TIP TIG takes the weld wire out of the welder's hands and consistently drives the weld wire into the optimum arc position. The result is uniform, consistent weld energy.

[] TIP TIG enables smaller diameter TIG weld wire which when combined with the higher energy (higher current) TIP TIG welds plus the Hot Wire current enable increased weld energy that results in superior weld fusion and decreased porosity and inclusion with any alloy weld.

[] The unique TIP TIG "agitated weld puddle" slows down the weld solidification and enables pore defects to exit the welds. The agitation dramatically increases the pipe side wall weld fusion and reduces the sensitivity to sluggish alloys and reduces weld stresses.

[] In contrast to any weld processes you are using on your pipe welds, the high weld speed TIP TIG welds that use EN polarity will produce welds with the lowest weld heat and the smallest possible weld HAZ. TIP TIG welds with always produce superior mechanicals and corrosion properties and the welds will always be the cleanest from the lowest oxidation produced.

Visit the manual and home section for more TIP TIG info.

 

TIG PIPE WELD COSTS AND WELD DEPOSITION RATES, A
SUBJECT RARELY DISCUSSED IN MANY WELD SHOPS:


I recently did a survey of TIG pipe weld personnel at some of the top engineering companies in North America. The companies included Westinghouse, General Electric, Siemans, Parsons and WSI, (Aquilex).

Weld Question. "Using a regular TIG 3/32 (2.4 mm) carbon steel or stainless wire,
what is the average wire feed length used per minute?

The Answer. The average regular TIG manual wire feed rate using 3/32 (2.4mm )wire was 6 - 10 inch/min. When you convert the average 8 inch/min with 3/32 wire to the 0.035 (0.9mm) wire that's commonly used with TIP TIG, that's approx. 56 inch/min of an 0.035 wire = approx 0.75 lb/hr. With an arc on time of 20 minutes per/hr that results in a regular TIG weld deposition rate range of 0.28 lb/hr, with 3- 5 inch/ min typical weld travel rates.





PIPE WELD COSTS. REGULAR TIG VERSUS TIP TIG:

TRADITIONAL TIG PIPE WELDING. TIP TIG PIPE WELDING.
BETTER QUALITY + 50 - 300-% MORE WELD EACH HR.


TIP TIG provides a dramatic solution for a weld industry that's facing
increased labor and weld rework costs and a shortage of skilled welders.

For a comparison of these two similar pipe welds, start the regular TIG welder on the left then start the TIP TIG video on the right and compare the TIP TIG process with the regular TIG process. The regular TIG welder like most highly experienced TIG pipe welders is working hard and depositing little weld. Which welder looks like he is the most comfortable and applying the most control of the weld? Which welder is depositing 200 - 300 percent more weld wire?

TIP TIG VERSUS REGULAR TIG WELD DEPOSITION RATE & ARC ON TIME:

Weld arc on times:
For this cost evaluation with regular TIG, I use an average hourly arc on time of 20 min/hr. In contrast to regular TIG, the TIP TIG process is a "semi-automatic process" with less needs for arc starts / stops, so I use an average hourly arc on time of 30 min/hr.

Regular TIG pipe fill pass welds and average pipe weld deposition rates.
 Watch any regular TIG welder feeding a 3/32 wire. You will note in approx 60 seconds that the welder typically deposits 6 - 10 inches/min. The average 8 inch/min of 3/32 TIG wire delivered would equal = 56 inch of 0.035 (0,9mm) wire. That 56 inches of 0.035 wire is approx, 0.8 lb/hr. With a 20 minute arc time, the regular, manual TIG welder when providing any pipe fill pass is typically depositing on average 0.27 - 0.3 lb/hr.

TIP TIG pipe fill pass weld deposition and pipe weld costs.
In the above video on the right, the TIP TIG welder is using an 0.035 wire reel. In contrast to the regular manual TIG weld depositing 0.27 lb/hr, a conservative manual TIP TIG 0.035 weld deposition for the vertical up fill passes on pipe
< 3/8 wall would average approx. 2 lb/hr. With the TIP TIG increased arc on time, TIP TIG delivers approx. 1 lb/hr.

In contrast to regular TIG depositing 0.27 lb/hr most TIP TIG pipe fill pass welds will each hour typically deliver between 200 - 300 % more weld. With rotated pipe, the TIG weld deposition increase is typically in the range of
200 - 400%.

TIP TIG, reduced weld preps and labor - consumable cost savings.
Another extensive weld cost benefit with the TIP TIG process is the improved weld surface tension and agitated weld pool improves the flow of weld metal and this usually enables a reduction in traditional pipe groove vee and J groove weld preps. For example if you are using combined vee preps of 60 - 70 degrees consider with TIP TIG using 40 - 55 degrees. With 40 degree included J- grooves consider 30 to 35 degress, These reductions in pipe edge preps can typically reduce pipe labor and consumable costs in the range of 20 to 50%.

TIP TIG less weld defects, less arc start - stops, less weld rework.
 The higher TIP TIG weld energy and unique agitated weld pool, when combined with the continuous control of the weld wire to the optimum arc position, results in optimum quality root - fill pass welds that in contrast to any other weld process will enable the lowest weld rework.

TIP TIG pipe weld wire and weld gas cost reductions.
You may be surprised to know that your regular TIG wire costs may be approx. 15 - 25% more than the 30 - 40 lb MIG wire reels you will purchase for the TIP TIG. When you can weld faster than regular TIG as you do with TIP TIG, you can readily reduce your weld gas costs. If that regular TIG weld requires an hour arc on time, the TIP TIG weld is typically done in 15 - 20 minutes, depending on your flow rates you will only require 25 to 40 % of the argon you would normally use for regular TIG.

TIP TIG first time optimum pipe weld mechanical and corrosion properties:
In contrast to the SMAW and the traditional TIG processes, the higher TIP TIG weld speeds not only reduce labor cost the increased weld speed also dramatically reduce the weld heat input providing less weld oxidation and smaller weld heat affected zones. The low weld heat is particularly beneficial with heat sensitive alloy applications.

In contrast to the Reverse Polarity pulsed MIG process, there is also a dramatic weld heat reduction from the TIP TIG Electrode Negative welds which dissipate the heat into the parts welded.

TIP TIG a weld solution for alloys that produce sluggish welds.
With the increased TIP TIG weld current combined with the hot wire weld current and agitated fluid weld pools, duplex, stainless, nickel alloys and high carbon steels are no longer sluggish so improved weld fusion and less porosity is attained. The TIP TIG improved weld fluidity with low weld heat is especially beneficial for duplex alloys as it provides greater control of the austenite / ferrite formation. Heat sensitive P91-92 applications thrive on the the higher TIP TIG weld speeds and the smaller HAZ. Inconel, Super Duplex, Stellites, Hastelloys, Stainless, Monel, Copper, Brass or Carbon steels, it does not matter what the steels or alloys are, the real world TIP TIG weld benefits will always be extensive.



GAS SHIELDED FLUX CORED FOR YOUR PIPE WELDS.
FCAW COSTS VERSUS TIP TIG WELD COSTS:

All position gas shielded flux cored versus TIP TIG weld data and weld costs. With vertical up, 0.045 (1.2mm) E71T-1 wire feed rates usually set between 200 - 350 inch/min (5- 9 m/min) (Ed's wire feed clock method 10 - 12 o'clock), flux cored on pipe typically deposits approx. 5 to 8.5 lb/hr.


YOU CANNOT USE THE FLUX CORED PROCESS ON CODE QUALITY PIPE WELD WITHOUT USING A GRINDER:

Flux cored arc on time will be influenced by slag and surface defect removal time. Typical hourly flux cored deposition with arc on time of 20 minutes/hr is approx. 1.7 to 2.8 lbs/hr.

With flux cored code welds expect to find weld slag, extensive porosity and lack of fusion weld defects. There will be weld wire quality concerns and extensive spatter. Small wire stick variations with this process can dramatically impact the weld parameters influencing the weld quality and of course always expect with flux cored excess weld heat and smoke.

WITH TIP TIG, YOU SHOULD NOT NEED A GRINDER: As TIP TIG should not require any weld cleaning between weld passes, TIP TIG allows an hourly increased arc on time. With a 30 min/hr arc on time, TIP TIG on many common weld applications can deliver 1 to 2 lb/hr typically with no weld defects, no spatter, the lowest weld heat, the lowest smoke and a uniform all position manual weld quality beyond any other weld process.

Pipe fill passes and TIP TIG versus Pulsed MIG. It's this simple, the TIP TIG process can compete with all position pulsed MIG deposition rates and arc on times while producing superior weld quality without the pulsed porosity levels and with superior weld fusion. Also TIP TIG enables lower weld heat, less distortion and the lowest weld fumes.



EXCELLENT, LOW COST PIPE WELD AUTOMATION

TIP TIG PIPE WELD WITH A ROTARY POSITIONER. .
 
With or without that positioner, the semi-automatic TIP TIG process provides the best root - fill pass weld quality

With any pipe weld position, the fill pass welds will typically deposit 100 - 400% more weld than that attained by any manual or automated, An 8 inch pipe would average approx just over a minute per fill weld pass.




5G PIPE FILL WELD PASSES MADE SIMPLE WITH TIP TIG.

 

Why welders like TIP TIG. No foot control is required and one or two hands can be used to control the torch. The lowest weld smoke will be generated. No weld spatter, no weld slag and no grinding required. Look how easy it is to make a pipe weld that is producing superior weld quality than regular TIG.

In contrast to regular manual TIG, with TIP TIG there is minimum weld starts and stops. The less oxidized TIP TIG welds are the cleanest welds you will ever see. The TIP TIG weld HAZ produced should be the smallest. The agitated TIP TIG welds should always provide superior side wall fusion with less pore / inclusion defects and the weld stresses generated should always be the lowest.


 

Add the TIP TIG process to our unique automated orbital, robot and ossicilator equipment and you
will have low cost solutions to providing the best possible automated pipe and clad weld quality.
For information on the unique patented TIP TIG product line, call Nick or Ed at 856 312 8164.
When your manual or auto weld process is easy
to use, and that process provides the highest weld quality with the lowest possible weld heat,
you will see some remarkable untouched weld quality results like this 5G (vert up cap pass) from Randy at the Plumbers - Pipe fitters (UA).



Note TIP TIG manual weld uniformity and continuity,
the minimum HAZ, minimum weld starts / stops. X- Ray = no defects.

 


INFORMATION ON ALL POSITION, CODE QUALITY PIPE WELDS & CONVENTIONAL WELD PROCESS CHOICES:

Most global companies who wish to produce all position “code quality pipe welds” will in 2011 be considering the following weld process options. The weld reality is none of these weld processes will provide the consistent, optimum weld quality that is attained from the TIP TIG process.

Traditional Manual TIG Pipe Welds. This 70 year old process typically uses low to moderate weld currant on pipe welds. The TIG current produces a fast freeze, small weld pool that restricts the manual weld deposition rate (manual wire feed rate) potential. With the inability of the manual TIG welder to feed small diameter weld wires such as 0.035 - 0.045 (0.9 - 1.2mm) ) at wire feed rates of more than one lb/hr, the manual TIG process has for decades had to use larger weld TIG wires which are typically in the 1/16 to 1/8 (1.6 to 3.2 mm) range.

The large TIG wire sizes used for those small, manual TIG pipe welds are typically made < 250 amps. The large TIG wires sizes normally associated with the wire used with SAW at weld current in the 400 - 800 amp range. As there is rarely sufficient weld current for the large TIG weld wires utilized, the manual TIG welder will use techniques in which the TIG weld wire is rapidly dipped in and out of the weld. The manual TIG wire feed function is an important weld skill with the TIG process, (a skill no longer required with TIP TIG).

Each minute, on average the regular manual TIG welder deposits approx. 6 to 10 inches of 3/32 TIG wire, a deposition that provides approx. 0.5 to 1 lb/hr. The low TIG weld deposition rates create high labor costs and the resulting slow TIG weld speeds can generate high weld heat creating mechanical or corrosion concerns especially when welding alloys.

The regular manual TIG process requires the highest "welder's skills" and TIG is the only process that requires on many welds the use of two hands and a foot control. The manual TIG pipe weld quality is influenced by the welders skills, by the Inconsistent, wire delivery to the optimum arc position, (the arc sweet spot). and the frequent weld wire changes that can generate arc start - stop weld tie in concerns.

Common manual TIG pipe weld defects are occasional lack of fusion, tungsten inclusions, hot cracks and small weld pores and inclusions that are influenced by the weld technique and the small, rapid freeze welds.

In contrast to MIG and flux core, the regular TIG process provides a higher arc temperature with lower weld deposition rates and TIG uses electrode negative which allows rapid dispersion of the weld heat into the parts being welded. Regular TIG also provides a more focused arc plasma and utilizes inert gases. These are the fundamentals that allow the manual TIG welder to generate higher weld quality than that possible with either the Pulsed MIG or Flux Cored process.


Cold Wire (CW) TIG: Take a small diameters weld wire, run it along side the TIG torch and feed that wire into the TIG arc and you have the highly sensitive, semi-automatic, CW TIG process. The CW TIG process is used for both manual and automated applications. While the constant fed weld wire enables a slight increase in the manual TIG weld "arc on duty cycle", it's important that the weld shop be aware that with manual welds, the CW process is not capable of producing weld deposition rates beyond that attained by a regular manual TIG welder who feeds their larger weld wire by hand.

With pipe welds or any welds in which weld torch manipulation, (walking the cup) is required, the CW process is rarely suited as there is no change in the rapid solidifying, small weld pool dynamics, and a small change to the the CW arc length can disrupt the ability to melt the constant fed weld wire. In contrast to the CW process, TIP TIG allows for a typical 100 - 300 increase in weld deposition with higher energy, agitated welds.


Traditional Automated Hot Wire (HW) TIG. Add 50 to a 100 amps to a constant fed TIG weld wire that's directed into the TIG arc and you provide more energy to that fast freeze, small TIG weld. This process is called Hot Wire TIG and typically this process is suited only to automated applications.

When used on vertical and horizontal welds or on any welds using low to moderate weld current, the HW process is sensitive to minor changes with the many variables that can influence the arc length and the placement of the constant fed weld wire into the optimum arc position.

To reduce the "HW arc length sensitivity", this process will typically use an
Arc Voltage Control. (AVC). The arc length weld sensitivity increases as the current required for the application decreases. Vertical up welds require less weld current making them much more sensitive to arc length variations than HW welds made in the flat position at higher weld current. (typically > 250 A)

Common Hot Wire TIG vertical up, automated weld defects will be minor lack of fusion, small weld pores and inclusions.

With the HW process and requirements for an automated Arc Voltage Control, the HW process is typically not suited for manual TIG welding. In contrast TIP TIG does not require an Arc Voltage Control which is evidence of it's decreased sensitivity to arc length variations. The change in the TIP TIG weld dynamics also enables higher wire feed rates that allow more weld current than many HW welds. With TIP TIG, the increased weld deposition rates, increased weld energy, less arc length sensitivity and unique weld pool agitation benefits, you have a process that is far superior to both the HW and CW processes.



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



THERE ARE TWO WELD PROCESSES THAT DON'T BELONG IN A PIPE WELD SHOP
THAT HAS A MANDATE TO DELIVER OPTIMUM, CONSISTENT QUALITY PIPE WELDS,
THE SMAW (STICK) AND THE SELF SHIELDED FLUX CORED PROCESS.


SMAW and Self Shielded Flux Cored Pipe Welds: It's remarkable in 2011, that given the available weld process choices, thousands of global weld shops will consider the SMAW or the Self Shielded Flux Cored Process for code quality pipe - vessel and fabrication welds. With pipe welds that require 100% x-ray or UT evaluation, the SMAW and Self Shielded Flux Cored processes should be the last processes considered.

SMAW is a weld process that has many " flux - slag concerns" all of which
lead to weld issues.

SMAW is a process in which you will find the electrodes are dramatically
different from one consumable manufacturer to another.

SMAW is a process in which you should always expect weld defects
especially at arc starts - stops and at weld tie ins.

SMAW is a process in which you should always expect to find lack of fusion, slag and pores.

SMAW is a process in which every welder brings different weld skills and techniques to the weld. It , should be no surprise to engineers when SMAW procedure welds do not comply with the weld results attained from the pre-qualified weld procedure.

Common SMAW weld defects which are frequently beyond the control of the welder are lack of weld fusion - excess porosity - entrapped slag - excess spatter - poor weld tie-ins - undercut - hydrogen cracks. To add to the common SMAW weld issues, the SMAW welder has frequently got to deal with hazardous weld fumes. The bottom line is SMAW is a weld process in which it's impossible to achieve consistent, optimum weld quality a weld process in which it's impossible to apply effective weld process controls. There will always be a place for the SMAW process, however any weld shop that takes pride in the welds it produces should not be considering the SMAW process.

Note if you want to know the numerous reasons why Self Shielded Flux Cored Wires do not belong on any weld project which desires consistent optimum weld quality, I recommend you visit the flux cored section at my web site www.weldreality.com.


Pulsed MIG Issues and Pipe Welds: The Pulsed MIG process has in the last three decades had many exaggerated electronic weld process benefit claims that may help the weld salesman promote this equipment, however this process should not be the process of choice for pipe weld shops that want to achieve consistent, optimum, manual quality with all position carbon steels and alloy welds.

[] Thanks to the Reverse Electrode Positive (REP) mode, the Pulsed MIG weld results in high concentrated localized weld heat at the MIG wire tip. The localized heat in the arc zone typically results in a large HAZ which may have a negative impact on many alloy applications.

[] The Pulsed MIG process is a Wire Stick Out (WSO) sensitive process, and the small WSO changes that typically occur with most manual MIG pipe welds can readily change the Pulsed MIG (current - voltage) weld energy delivered to the weld by 10 - 25 %. With pipe welds, the manual WSO changes can cause lack of weld fusion, increase the weld porosity or when welding duplex pipe provide changing, unacceptable ferrite levels.

[] The Pulsed MIG arc energy constantly fluctuates between a typical peak current range of 380 - 450 amps to a low 60 - 120 amp back ground range. The pulsed MIG parameter changes influence the weld energy delivered. The pulsed MIG process enables high weld deposition rates for pipe welld, however there are few weld benefits attained when that weld transfer mode spends 50% of its time with the low back ground current.

The fluctuating pulsed MIG parameter changes with healthy pulsed MIG weld deposition rates that promote fast weld speeds. The pulsed MIG weld mass to weld energy ratio is poor for the weld speeds generated. Even with highly skilled MIG pipe welders, the pulsed MIG mode will generate lack weld fusion especially in the first two weld passes over the root. This process becomes more defect sensitive with wall thickness > 6 mm, or when welding sluggish alloys such as duplex or stainless.


Pulsed MIG weld issues for your pipe welds, especially
when welding pipe wall > 6mm will be influenced by;

(a) the pulsed MIG weld sensitivity to WSO parameter changes,
(b) the Peak to Back Ground weld current changes,
(c) the erratic performance of many pulsed MIG power sources,
(d) the general lack of process control expertise,
(e) poor weld techniques,
(f) poor settings.
(g) poor weld wire and reactive gas.
If your MIG pipe welds is subject to 100% X-Rays look for pores - inclusions and lack of fusion weld defects that will influence weld failure. Those defects are typically found in the root and first two passes over the root.

E-Mail to Ed 2012: Hello Ed; I was reading a bit of your weldreality.com website on pulsed MIG equipment. My company purchased the Miller Pipeworx 400 about 5 months ago. I will admit we bought it because of the pulsed MIG and RMD sales pitch, I wish I had come across your site or books beforehand.. oh well. This machine was presented to us as the be all, end all for pipe welding. I will admit I was impressed by the RMD root feature on the machine. We weld various piping, from water, steam and gases and different diameters and schedules. We perform a lot of code work as well (ASME B31.1 for eg.). Since purchasing the equipment I have done over 10 tensile test plates, and we have consistently seen weld flaws in the breaks. Although we are achieving good tensile values, we see these voids in between the root and the Pulsed fill. The Miller rep has not been much help, they have that kind of not sure attitude, and are always leaning towards welder or parameter errors with the welds. I understand what you say about standard CV MIG machines, as I have used these extensively in my 20 + year welding carreer. I am not overly impressed with this pulsed stuff (aluminum welds yes !!!) . We are getting a little frustrated and now I am looking at TIPTIG. Anything you can do Ed would be appreciated.
Regards PG.
Weld Supervisor.
AC Ltd.
Canada.

Note: It does not matter who makes the pulsed MIG weld equipment, the pulsed MIG weld dynamics are such that this process is simply not ideal if "defect free welds are required from manual welders". At my web site weldreality.com, and in my 600 page book, "A Management Engineers Guide to MIG, weld Quality - Costs - Training" published in 1996, I have wrote more than 130 pages on the pulsed MIG process and described the common weld issue that will occur with carbon steels - alloy steels pipe welds. Weld issues such as;
(a) Arc instability.
(b) Lack of weld fusion and porosity from too much weld deposition that results in fast weld speeds and welds made with too little weld energy, especially when the welds are made on all position welds made on steel parts > 4 mm.
(d) I wrote about the difficulty encountered with maintaining essential MIG weld procedure variables with pulsed MIG equipment that changes from one pulsed MIG equipment mfg to the next and from pulsed MIG equpment that evolves every few months or every time another bell or whistle can be added.

Sixteen years later, the same pulsed MIG problems exist. For extensive info on the pulsed MIG process and equipment issues, visit the pulsed MIG section at my other web site www.weldreality.com..


Gas Shielded Flux Cored Pipe Welds:
While superior to the SMAW process, the gas shielded flux cored process will provide extensive weld quality issues with any all position pipe welds.

When you pick up that reel of 0.045 (1.2mm), 71T-1, flux core wire, be aware that in the average 20 lbs per/shift used per welder, there should be concern that
(a) the flux has not absorbed moisture,
(b) the flux alloy content composition and flux content
are optimum and consistent throughout the wire,
(c) the extensive differences between the flux cored
wires from the different FCAW wire manufacturers,
(d) the influence of incorrect pipe weld technique with
the fast freeze, thin slag process.
(e) the dramatic influence of wire stick out changes on the low to moderate parameters used,
(f) the propensity for slag entrapment irrespective of the way the weld is made.

With all position flux cored welds, you can have the best welder in the State, and if the welds are required to have 100% X-Ray evaluation, most weld shops will have to deal with weld repairs from lack of fusion, slag inclusions and excess porosity. The welders also won't thank you for the spatter and excess weld fumes.

MIG Short Circuit - MIG STT and MIG RMD Pipe Welds. While these MIG processes are suited to "open root pipe welds", the weld manager should be aware that using these weld processes adds to the complexity of the application and pipe procedures as the welder has to switch to another weld process for the fill passes.

With these process, there is also concern with attaining consistent pipe root penetration and optimum weld quality with the common root gap and alignment deviations found in the typical pipe shop. There should always be a special concern when welding high alloy 5G root applications where the weld shrinkage and sluggishness with the alloys adds further weld issues.

It's one thing to weld pipe open roots with controlled, machined joints and it's another thing to weld a pipe to an elbow that has ID alignment issues or a root gap which is much smaller or larger than 3 mm. While short circuit is well suited to rotated pipe root joints with controlled gaps and no alignment issues. The STT and RMD processes can weld roots in any pipe weld position, however these two weld processes have narrow, optimum, weld parameter ranges that are poorly suited to deal with weld root variations and sluggish alloy welds.

IF WELDING CARBON STEEL PIPE ROOTS AND THE PIPE IS ROTATED, THE MIG SHORT CIRCUIT MODE FROM ANY
LOW COST CV POWER SOURCE, IS JUST AS EFFECTIVE AS THE HIGHER COST STT - CMT - RMD MIG EQUIPMENT.

Note: The fast freeze MIG root welds require "reactive gases" which contribute to the common oxide pore defects found in MIG root welds. For extensive real world pipe data on the three MIG processes discussed, visit Ed's www.weldreality.com and select the process in question, or examine the world's most effective MIG - Flux Cored Weld Best Practices and Process Control Training Resources also at weldreality.com.

In contrast to the above weld processes, when considering TIP TIG, remember this process can make excellent all position root welds and if required this process can also be used as a regular TIG process suited to any root weld variations. For pipe root and fill pass welds or any applications, it's worth noting that TIP TIG provides the most extensive amp range available from 50 to 500 amps. With TIP TIG pipe root welds, TIP TIG will provide the highest energy, with consistent wire to arc placement. With TIP TIG there is no unnecessary arc starts / stops (tie -in concerns) and no sensitivity to WSO changes as typical with MIG and flux cored.



In contrast to regular TIG, with the TIP TIG process expect 200 - 400% more pipe
weld production each hour with much superior weld quality.


[] This TIG pipe wire feed, (weld deposition) rate average was 240 - 280 inch/min.The above TIP TIG pipe weld was made by a Westinghouse welder.

[] You will typically attain 50 - 100% productivity improvements in the root and
200 to 400 % improvements in pipe fill pass deposition rates.

[] Higher TIP TIG wire feed capability enables increased TIG weld current capability. Also in contrast to the regular TIG process, the agitated weld pool and increased TIP TIG weld energy enables superior side wall weld fusion and lower porosity / inclusion content.

[] The TIP TIG Weld Agitation and Hot Wire current is especially beneficial for improving the weld fluidity with all sluggish alloys such as duplex and stainless.

[] TIP TIG provides much faster manual and automated TIG weld travel rates that enable the capability to always produce any welds with the lowest possible weld heat and the smallest possible HAZ. With the lowest oxidation potential and the weld agitation, with TIP TIG, you can expect the cleanest possible multi-pass welds with the lowest weld porosity and inclusion content.

[] With TIP TIG, the weld shop should anticipate producing manual or automated welds and parts with outstanding consistent quality beyond that attained with regular TIG, Pulsed MIG and flux cored.

[] Consistently attaining optimum mechanical or corrosion properties or for example ferrite content in duplex welds, becomes a simple task with the TIP TIG.

Note: Companies such as Exxon, Westinghouse and WSI (Aquilex) lead the way in the USA developing new 5G, TIP TIG pipe procedures with typical, manual wire feed rates 200 - 400 % greater than that attained by regular manual TIG welders.




THERE IS NO WELD PROCESS CAPABLE OF CONSISTENTLY PRODUCING THE OPTIMUM
PIPE WELD IMPACT PROPERTIES THAT CAN BE ATTAINED WITH THE TIP TIG PROCESS:


WELDING P91. ASME SA 182-F91. ASTM A199 Grade T91.
WHY TIP TIG ALWAYS ATTAINS THE BEST POSSIBLE IMPACT PROPERTIES.

LEFT PICTURE. TIP TIG UNTOUCHED
P91 WELDS MADE BY SIEMEN'S WELDER.

With applications such as P91, Duplex or any Alloy pipe - fabrication welds in which there is a need to attain specific weld Impact Properties or consistent, optimum Ferrite Levels, weld shops understand that it's often difficult for manual welders to conform to the original Stick -TIG - MIG and Flux Cored Weld Procedure Qualification that attained the desired weld quality and weld - part properties.

With each of the four processes mentioned, you can have the best manual pipe welders, yet as a result of the inconsistency and lack of uniformity with the welder's techniques, the general lack of best weld practices and process controls, the Achilles Heels of each weld process, (as spelled out at this site ), the weld shop will too frequently attain unacceptable weld quality and unacceptable weld - part mechanical properties.


In contrast to manual regular TIG - Pulsed MIG and Flux Cored processes, the manual, semi-automatic TIP TIG process always provides the highest possible weld quality with the lowest possible weld heat. TIP TIG provides an opportunity for the weld shop to implement "uniform weld best practices / process controls and improve the consistent conformance to the weld procedure qualifications.

P91 impact values attained from the manual TIP TIG welds. ISO-V(J) at 20° 100-120 J.

TIP TIG and P91 Pipe Welds: If traditional TIG was used for the root and SMAW for the P91 fill passes, it would take approx. 240 minutes to do each of the critical "P91 pipe joints shown. Using one process TIP TIG, it would take approx. 65 minutes to produce defect free welds with much lower weld heat.

Note: If instead of SMAW you used the traditional TIG process for the fill passes, the slow weld speeds would be applying "excess weld heat" to the heat sensitive P91 pipes.

The TIP TIG process was qualified by SIEMENS in Germany for both the P91 root and for the pipe fill passes. With an application like this, depending on the welder, in contrast to regular TIG, each hour the TIP TIG fill pass welds would deposit an average of 200 to 300 % more weld. Using the TIP TIG process Siemens attained the best weld quality (zero defects) and the best mechanical properties it had ever attained on any P91 pipe applications.

Apart from the superior weld quality from the TIP TIG process, weld shops benefit with a process that [a] gets the job done faster,
[b] provides the highest possible weld quality,
[c] provides great operator appeal,
[d] provides no spatter,
[e] requires no weld grinding or cleaning,
[f] provides the least weld fumes and weld dust particles
[g] provides the lowest possible weld joules, the smallest HAZ. the least distortion and the best possible mechanical - corrosion properties.




P91 Steels and other Creep Strength-Enhanced Ferritic Steels:
None of the following weld processes, regular TIG - Pulsed MIG - SMAW or Flux Cored can provide the multi-pass weld quality that TIP TIG will deliver from the root to the cap passes.

The TIP TIG pipe welds will require less skills and always produce the best mechanical properties due to the lowest possible weld heat input. Siemens reports that when welding P91 pipe with the TIP TIG process, it attained the best weld results and the best mechanical properties it's ever achieved.





WHEN PIPE WELDING, IT'S BENEFICIAL TO UNDERSTAND WHAT TIP TIG CAN ACHIEVE IN CONTRAST TO THE REGULAR MANUAL TIG PROCESS:

Manual TIG pipe welds are made by welders who use their unique variable skills and techniques while delivering inconsistent wire feed rates into different areas of the small, rapid solidifying weld pool.

Primary issues with the traditional manual TIG process;

[] The inability for the manual TIG welder to ensure their weld wire is always fed consistently into the rapid freeze weld, small plasma sweet spot in the arc and weld, impacts weld quality, weld uniformity and consistency.

TIP TIG always directs the weld wire to the arc sweet spot providing uniform, consistent weld energy.

[] The inconsistent manual TIG "wire feed" rates utilized, impacts weld quality, heat (joules) and productivity.

TIP TIG provides constant fed weld wire that dictates the weld travel rates and regulates the weld joules.

[] The common TIG low deposition rates influence weld labor costs, the weld energy produced and the weld dynamics. The low deposition also impacts the weld current that can be used, the weld travel rates, weld distortion, weld joules input and weld oxidation.

TIP TIG provides deposition rates that are typically 100 - 400% greater than regular TIG welds and
the benefits from the increased TIP TIG weld speeds are extensive.

[] The numerous TIG arc starts and stop (weld tie-ins) influenced by the manual weld wire changes,
impacts weld quality, weld appearance and add to weld skill requirements.

TIP TIG eliminates this concern.

[] The high TIG skill requirements for feeding the wire, manipulating the torch and sometimes operating a foot control, impacts training time required and the adherence to pre-qualified weld procedures.

TIP TIG can use one or two hands on the torch and does not need a foot control so this process is
much easier to use.





TIP TIG INCONEL 800 PIPE . WELDED WITH INCONEL 82 WIRE.
Pipe 10" ID PIPE WITH 3/4 (18 mm) Wall.


TIP TIG Weld Cycle Time 30 - 40 minutes.
Customer used to takes 4 hrs with TIG.

No brushing. No grinding. No spatter. No foot control. Much less skills than TIG.
No weld rework. Constant weld fusion and improved conformance to weld procedures. Cleanest welds from lowest possible oxidation and from lowest weld heat input ensures lowest possible pores and inclusions. Note weld smoke is from vee prep machining lubricants.





All Position Nickel Alloy Welds:

None of the following weld processes, regular TIG - Pulsed MIG - SMAW or Flux Cored will provide the weld quality that TIP TIG will deliver to all Nickel Alloy applications. TIP TIG will produce the lowest possible weld heat and lowest weld oxidation potential. TIP TIG has little concern for sluggish alloys producing welds with superior weld fusion and the best weld and part mechanical / corrosion properties.




TIP TIG PIPE ROOT WELDS.

TIP TIG is a weld process that has the greatest tolerance for pipe root dimensions and alignment deviations and of course TIP TIG will always produce thre best fill pass weld quality.


TIP TIG pipe root welds are typically made 50% faster than regular TIG, however TIP TIG roots also provide superior weld quality. Weld start / stops are reduced for most 5G root welds and the weld is much more uniform and consistent.

Note the uniform, clean unoxidized root appearance. The welder at the weld end raised the torch too quickly loosing the post flow gas coverage.

In contrast to the MIG STT - RMD processes the TIP TIG are superior quality (not influenced by reactive gas mixes) and the welds have much greater tolerance for root gap and alignment dimension deviations.

The TIP TIG pipe "fill passes" are typically made 100 - 400 % faster than regular TIG.

Click here to see the other half of the root.





WHEN IT COMES TO CHOOSING THE PROCESS THAT WILL DELIVER THE BEST WELD QUALITY AND THE BEST MECHANICAL - CORROSION PROPERTIES, YOU WILL FIND THAT NO OTHER WELD PROCESS CAN PROVIDE THE CONSISTENT, OPTIMUM WELD QUALITY THAT TIP TIG CAN DELIVER TO ANY ALL POSITION WELD MADE ON ANY ALLOY.





TIP TIG. Controlling weld heat.
Controlling Ferrite - Austenite with duplex welds:



WELD HEAT - WELD HEAT - WELD HEAT - WELD HEAT.

THE WELD PROCESS SELECTED & THE WELD JOULES DELIVERED:

When welding pipes in the 5G position and "optimum weld fill pass parameters" are utilized, it's interesting to note the radical weld joules/inch (weld heat) differences between Regular TIG, Pulsed MIG and Flux Cored with the TIP TIG process;

Weld Joules and Regular TIG pipe fill pass weld parameters: Typical pipe fill pass weld parameters
13 volts. 135 Amps. Average weld travel rate - 3 - 5 inch/min. With 13 Volts x 135 Amps x 60 divide by 4. You will typically produce regular TIG pipe fill pass welds that generate approx. 26325 joules/inch.

Weld Joules and Gas Shielded Flux Cored - Pulsed MIG pipe fill pass weld parameters: Typical weld parameters with 045 (1.2mm) wires. 23 - 27 volts. 140 - 220 Amps. Weld travel rate 10 - 15 inch/min.
With 25 Volts x 190 Amps x 60 divide by 12 inch/min. You typically will produce pipe fill pass welds that generate approx. 23750 joules/inch.

Weld Joules and TIP TIG pipe fill pass weld parameters: Typical TIP TIG weld parameters. 13 volts. 200 Amps.
Weld travel rate 10 inch/min. 13 Volts x 200 Amps x 60 divide by 10 inch/min = 15600 joules/inch.

Combine the TIP TIG lower joules with the EN weld heat dissipation benefit and the result is TIP TIG will always delivers the lowest weld heat, the smallest weld HAZ, the least weld stresses and distortion. TIP TIG not only provides welds with superior mechanicals and corrosion properties this process should enable lower pre-heat when pre-heat is required.

WHILE WELD CODES DO NOT CONSIDER THE INFLUENCE OF ELECTRODE NEGATIVE VERSUS ELECTRODE POSITIVE ON THE WELD JOULES AND IT'S IMPACT ON THE WELD HAZ, THE EN POLARITY DOES IMPROVE THE WELD HEAT DISPURSEMENT WHICH LESSENS THE INFLUENCE OF THE WELD HEAT IN THE WELD HAZ.



CONTROLLING FERRITE WITH DUPLEX PIPE WELDS IS MADE SIMPLE WITH THE TIP TIG PROCESS.

The volume percentage of ferrite present in duplex stainless steel clad metals will influence both the mechanical and corrosion properties.

Both strength and stress corrosion
cracking resistance may be reduced when the FN is less than 30.

There will be is a loss of ductility and toughness of the clad metal when the FN is above 70 in duplex.

Note, As indicated in the left report,the first time (no play around) ideal ferrite volume percentage consistently attained with the TIP TIG process as indicated in the report shown on the left.

Consistent control of the Ferrite is essential to achieve optimum corrosion resistance and
mechanical properties, yet the sad reality of pulsed MIG and flux cored is a change in the gun angles or a change in the wire stick out can dramatically impact the weld heat and ferrite volume.


WHEN TRYING TO ATTAIN CONSISTENT OPTIMUM FERRITE LEVELS WITH DUPLEX WELDS OR CLADD WELDS, IT CAN BE A FRUSTRATING CHALLENGE WHEN USING THE PULSED MIG AND GAS SHIELDED FLUX CORED PROCESS. IN CONTRAST, ATTAINING OPTIMUM, CONSISTENT MECHANICAL - CORROSION PROPERTIES IS SIMPLE WITH THE TIP TIG PROCESS. WITH TIP TIG THERE IS NO WELD FUME CONCERNS, NO WELD SPATTER, NO WELD CLEANING AND TIP TIG ELIMINATES THE NEED FOR USING MORE THAN ONE PROCESS FOR PIPE WELDS.

Control of Ferrite - Austenite levels is a critical requirement when welding Duplex alloys.

Duplex Welds. The Ferrite Number decreases with a rise in the "weld part heat" and with increased weld dilution. Both pulsed MIG and flux cored will typically provide higher weld part heat input than a TIP TIG weld and the manual MIG - FCAW weld heat will be always be more inconsistent .

Note: In contrast to pulsed MIG and flux cored, with the TIP TIG process, the weld HAZ should be always smaller and the lower weld / clad weld heat input will be easier to control.


Duplex Welds. Pulsed MIG - FCAW Wire Stick out changes:
The Ferrite Number in those duplex pipe welds decreases with a "rise in welding current" and an increase in weld speed.

With pulsed MIG and flux cored, a slight decrease in the wire stick out can increase the weld current in the range of 10 - 20% decreasing the Ferrite level.

A slight change in gun angle can extend the wire stick out which can increase the Ferrite level.

Note: With TIP TIG welds, torch angle changes will not influence Ferrite levels and there is no wire stick out change.


TIP TIG ON ALL ALLOY WELDS SHOULD PRODUCE SUPERIOR MECHANICALS & CORROSION PROPERTIES.

Think about the many alloy pipe weld benefits when considering TIP TIG. With most alloys welded with traditional TIG, the weld shop primary concern is usually from the slow weld speeds and resulting high weld heat delivered to the parts. TIP TIG enables much faster weld speeds which create the opportunity to reduce the weld joules to levels never before attained with any other weld process.




Welding a Duplex Heat Exchange Vessel.

When pulsed MIG and regular TIG failed at attaining full penetration open root welds on this duplex heat exchanger, the company selected TIP TIG. The TIP TIG process produced the highest, consistent weld quality with the lowest weld heat and the best possible duplex properties.




TIP TIG 5G PIPE FILL MADE SIMPLE.

 
A TIP TIG weld like this, depending on the wall thickness or pipe diameter is typically made at 100 - 400 % faster than regular TIG. Look how easy it is to make a pipe weld that always produces superior weld quality than regular TIG.

With TIP TIG - lowest weld fumes - no spatter - minimum weld starts - stops - cleaner less oxidized welds - smallest possible weld HAZ along with agitated welds that enable superior
fusion, less pore weld defects and lower weld stresses than regular TIG.


 

With TIP TIG you can consistently control
the weld wire delivered to the sweet spot in the TIP TIG arc.
TIP TIG is a process in which you can "apply the most manual weld process controls" to any weld application.

TIP TIG PIPE ROOT First time user.

TIP TIG PIPE FILL First time user.






WITH ANY WELD PROCESS, WHEN CONCERNED WITH MAINTAINING CONSISTENT
WELD QUALITY, TWO HANDS CAN BE BETTER THAN ONE:



 

With TIP TIG. The TIP TIG welder requires no foot control. The TIP TIG welder can use one hand to steady himself on the pipe, or use two hands to provide further stability to the weld torch. Don't forget the TIP TIG pipe welds also reap other benefits from the controlled wire feed input, the constant wire feed to optimum arc position, no weld starts / stops, higher wire feed rates and lower weld heat input, higher weld current and that unique agitated weld puddle, all combine to produce superior pipe weld quality and productivity.





 

Welding Chrome Moly Pipes - Valves and Fittings on high strength - low temp parts and high temperature - good corrosion property parts that require concern for temper embitterment, charpy V-notch values or attaining a low X - Factor.

Note (the X-Factor is a formula that measures the welds resistance to the loss of toughness that will occur when the weld is held or slowly cooled through the temp range of 850 - 1100F). All position gas shielded flux cored consumables are often used for these Chrome Moly applications.

[] As TIP TIG provides much lower weld heat input than the regular TIG - Flux Cored and Pulsed MIG processes, TIP TIG can provide the smallest possible HAZ and the lowest possible X Factor.

[] Unlike Flux Cored consumable which may have flux issues such as inconsistent flux composition, or moisture in the flux. With TIP TIG there will never be cause for concern with consumables and hydrogen content.

[] Ref charpy values. In contrast to the flux cored process which always creates concerns for trapped weld slag and excess weld porosity the TIP TIG process enables the cleanest possible welds with less internal defects than any other available manual weld process.

[] While flux cored is not suited for pipe open root welds and this process should provide concerns for the pipe fill pass as extensive parameter changes will occur with a slight change in the wire stick out. In contrast, TIP TIG can provide more weld controls than any other process for any weld position pipe root or fill pass. The bottom line, if the weld consumable is available on a MIG reel it can be used for TIP TIG, so before going down the flux cored path consider the TIP TIG benefits.

[] For those looking at Pulsed MIG on these pipe applications, please note you will not attain the weld quality achieved with TIP TIG and of course this process will weld the root to the cap.

 

 

AS THE EDGE WETTING ON THIS TIP TIG, 45 DEGREE "INCLUDED VEE ANGLE"
WELD INDICATES, TIP TIG CAN ENABLE A
DRAMATIC REDUCTION IN REGULAR PIPE / PLATE VEE - J GROOVE ANGLES.



TIP TIG. From the pipe root to the fill passes, when you attain the highest
weld quality with good deposition rates you achieve the lowest weld cost.

 

 

Regular TIG, an old process that will produce inferior weld quality,
require higher skills and higher costs when welding a pipe joint:

 
Highly Skilled Regular TIG welder. Note the welder sets 150 amps. In the 2 min 40 sec arc on time of the first pass he uses approx 22 inches of his 3/32 wire. The 22 inches of 3/32 equals an approx. 3/32 wire feed rate of 8 inch/min x 7 = 56 inch/min of 0.035 wire.

In contrast, TIP TIG on this pipe would have used a minimum of 160 - 200 inch/min of 0.035 weld wire and use around 250 amps with 80 additional Hot Wire Amps.

Each hour TIP TIG would deliver > 200% more fill pass weld for the all position welds. The TIP TIG welds would provide superior weld fusion and less porosity.

The TIP TIG welder would require less skills - dexterity and have less welder fatigue. With the all position welds, the TIP TIG welds would be more continuous and more uniform. The TIP TIG welds would enable the lowest possible weld heat producing the lowest weld fumes and best possible metallurgical properties.

 


TIP TIG FILL PASSES.

 

TIP TIG fill pass before the cap. This TIP TIG weld is better quality than most automated welds that use costly weld automation equipment. The manual TIP TIG welds will provide higher weld deposition.



COMPARE TIP TIG PIPE WELD DEPOSITION
RATES WITH REGULAR TIG PIPE WELDS.

TIP TIG versus
regular TIG Data.

 TIP TIG.

PIPE ROOT QUALITY: TIP TIG Manual Welds. With less arc starts / stops and an agitated weld pool, TIP TIG provides superior root and fill pass welds that are more consistent and uniform.

TIP TIG Pipe root production: Roots typically 50% faster.

TIP TIG Pipe fill production: TIP TIG 100 - 400% faster

TIP TIG horizontal fillets.
200 - 400% faster.

TIP TIG wire / gas cost considerable savings.








During 2011, the largest sub sea oil company in China, the China National Offshore Oil Corporation, (CNOOC) was looking for a weld solution for its 20 mile sub sea pipe project. The sub sea pipe ID was clad at the ends with Inconel. The manual and automated inconel welds were made on a ship.

CNOOC engineers had tried regular TIG and the most sophisticated pulsed MIG equipment available for the inconel clad and 5G welds, the bottom line the weld quality - productivity results were never satisfactory.

The Chinese came to the USA. With a few hours of weld evaluation at our facility, the Chinese engineers selected the TIP TIG process for both the all position manual and automated welds. More info below.



DON'T TRY THIS WITH THE REGULAR TIG OR PULSED MIG PROCESS.


2 LAYERS OF "UNTOUCHED" INCONEL, CLAD WELD IN THE PIPE ID: Note with this TIP TIG clad automation that no Arc Voltage Control was required. With the regular TIG and Pulsed MIG process you are unable to attain a clad weld or pipe weld with the quality and consistency that can be attained by the TIP TIG process. With this type of application you attain the lowest weld dilution, the lowest distortion, no weld fusion or porosity concerns, no spatter, no weld cleaning no weld fume concerns and for 100% X-Ray welds no weld rework. See finished weld below.


IN AN INDUSTRY IN WHICH IT''S DIFFICULT TO FIND SKILLED WELDERS.



TAKE NOTE THAT ON MOST TIG APPLICATIONS IT TYPICALLY TAKES
2 TO 3 TIG / SMAW WELDERS TO DO THE WORK OF ONE TIP TIG WELDER.




TIP TIG THE WELDERS CHOICE
FOR PIPE WELDS.
REGULAR TIG AND PULSED MIG CANNOT DELIVER THE MANUAL OR AUTO PIPE WELD QUALITY ATTAINABLE FROM TIP TIG.

 

Depending on the pipe diameter and wall thickness, TIP TIG pipe fill passes typically provide 100 - 500 % more weld than a manual TIG welder.

With TIP TIG foot controls not required. TIP TIG enables one or two hands on the weld torch. With TIP TIG you can eliminate the skills required to feed the weld wire.
The TIP TIG wire is always directed in the optimum arc location. Manual weld travel rates are more constant. Lower weld heat, less fumes.

Manual TIP TIG ROOT pipe welds typically
made 50% faster than TIG and the welds. These weld should look like automated pipe welds.


 


When you combine the world's best manual pipe welding process with our unique, cost effective automated weld - clad equipment, you have the potential to provide extraordinary pipe weld quality and productivity benefits.

For sales - service - quotes - parts, or if you wish to send weld samples,
E-Mail, nick@tiptigusa.com. Phone Nick Corso, 856 312 8164.

For optimum TIP TIG weld data or any weld application questions,
E-Mail, ed@tiptigusa.com. Phone Ed Craig, 828 337 2695.

Please note, It's no good calling your local weld distributor about the TIP TIG process or
the automated weld equipment, they don't have it.

We are looking for TIP TIG dealers in
Canada - Brazil - Australia. EMail Tom at tom@tiptigusa.com.

 

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



For the best way to optimize MIG and flux cored welds visit www.weldreality.com

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