The Cold Wire 
TIG process is very arc length sensitive and often while the wire is being fed it not  continuously melt in the arc plasma. Cold wire deposition rates if compared with regular manual TIG welds, are about the same, so there are no TIG weld productivity or weld speed benefits. TiP TiG enables 100 to 300% more weld wire to be deposited. The increased 
TiP TIG deposition  enables faster weld speeds which dramatically lower the weld heat. 
TiP TiG increased weld wire enables higher weld current than Cold Wire TIG. The TiP TiG  greater weld energy combines with the agitated
weld weld pool and lower weld heat, provide numerous  weld quality, productivity and costs benefits.
As we are all aware, due to the arc length sensitivity issues, the Hot
wire process requires an Arc Voltage Control, making this process unsuited
to most manual TIG welds. TiP TiG overcomes the arc sensitivity issues
and TiP TiG enables higher wire feed rates and superior weld quality.
 This reduced TiP TiG arc length sensitivity makes TiP TiG a good process
when weld automation is required.

TiP TiG will provide extensive weld benefits,

  • when welding alloys and code quality welds
  • when less distortion and stresses are beneficial
  • when clean welds with lowest porosity is beneficial
  • when the best possible mechanical – corrosion properties are required
  • when multi-processes are being considered
  • when reducing TIG – SMAW labor costs is beneficial
  • when reducing all position weld skills is beneficial
  • when producing welds that should not require cleaning is beneficial
  • when producing welds with the least weld fumes is beneficial

Note: We rarely recommend TiP TiG for aluminum welds as the process 
will be compared with pulsed MIG and spray and there may be wire 
feed issues especially with the softer wires such as 4xxx.

On many pipe applications, TIG is used for the root and other 
passes may be used for the fill passes. TiP TiG provides optimum
root welds and the best quality fill pass welds at much lower weld costs
than TIG welds. TiP TiG is easier to use on the root as the welder 
does not have to feed a weld wire or use a foot control. On long root
passes TiP TiG provides superior weld uniformity, continuity and quality.
 With the increased arc on time the root weld time should be less.
In contrast to TIG and SMAW, expect > 200% more weld deposition. TiP TiG welds typically should require no weld cleaning 
and with less weld heat reduce weld heat concerns for interpass temp controls. 
In contrast to all other weld processes you will attain the lowest possible 
weld heat (see heat below) with TiP TiG and the highest weld quality (see quality below). 
TiP TiG provides the weld wire constantly into the arc sweet spot for
 uniform weld consumable melting and the constant fed TiP TiG wire
 drives constant weld travel rates. In contrast to Pulsed MIG, with TiP TiG you will have 
superior weld fusion with less weld porosity and less weld heat. In contrast 
to flux cored and SAW with TiP TiG you will not have slag – flux – porosity issues and 
you will always provide superior weld quality with lower heat.
To go along with the TiP TiG unique wire feeder which vibrates the weld wire
 and the TiP TiG hot wire power source which preheats the wire, you need a TIG power
source that can communicate with the other equipment. We have tested many TIG power
sources and we find the Miller MaxStar not only provides the T2 – T4 communication 
it also provides ideal arc characteristics with low weld price.
When you increase TIG weld speeds you produce a weld with low 
voltage which combined with the faster weld travel rates lowers the weld 
joules. In contrast to all other available manual weld processes which 
use reverse polarity, (majority of weld heat focused in the arc zone, 
TiP TiG uses electrode negative in which the majority of the weld heat 
is dispersed into the base metal (good heat sink).
When you can provide a combination of high weld energy, 
an agitated weld pool, the lowest weld heat input and an inert shielding 
gas you should always expect the highest weld quality.
The TiP TiG process provides the highest possible weld energy and
agitates the fluid weld pool enabling superior weld fusion and less porosity
 with all sluggish alloys.
If you are welding with regular TIG, with TiP TiG for every three skilled 
TIG welders, (difficult to find) you can do the work with one TiP TiG welder.
 For every dollar you spend on weld rework you should eliminate that cost and  if reducing your TIG weld gas and wire costs is important, TiP TiG dramatically 
reduces those costs.