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 powersource that can communicate with the other equipment. We have tested many TIG powersources 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.
Why is there less concern with TiP TiG when welding sluggish alloys such as stainless, duplex and nickel alloys?
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.