TIP TIG WELDING
Industries and the Weld Benefits from TIP TIG
All weld applications benefit from a weld process such as TIP TIG which eliminates weld fusion or sluggish alloy concerns. This process also enables Vee groove dimensions that also dramatically reduce weld labor and consumables costs.
What weld shop wont benefit when they only have to use only one weld process such as TIP TIG which requires, one gas, one weld wire, one procedure and typically no more than two common weld settings for all welds.
TIP TIG while providing the highest weld energy in an inert atmosphere provides the lowest possible weld impurities and porosity, the lowest weld oxidation that produces the cleanest welds.
TIP TIP is the only weld process that will eliminate concerns for distortion, weld cracks and weld stresses. TIP TIG creates welds that produce the smallest weld HAZ eliminating, corrosion, mechanical property concerns. And also reducing or eliminating pre-heat, interpass temp, or post heat requirements.
What weld shop will not benefit when there is no weld spatter, cleaning, grinding and achieves least possible weld fume concerns.
In the Welding Process section, there are comparisons between TIP TIG versus Pulsed MIG, GTAW, Flux Cored, and the Hot Wire TIG process
Manual TIP TIG, in contrast to GTAW, Pulsed MIG and Gas Shielded Flux Cored, enables higher arc weld energy with superior weld wetting, which will provide superior weld fusion, which especially benefits sluggish alloys like Stainless, Duplex and Inconels.
Pulsed MIG and Flux Cored utilize reactive gas mixes, while TIP TIG uses inert argon. With steel welds, TIP TIG also enables the use of steel weld wires with lower deodorizers such as silicon and manganese. TIP TIG will ensure in manual or weld and clad applications the lowest possible porosity.
Those that use Pulsed MIG GTAW and Flux Cored on 5G pipe welds, will when using TIP TIG find from the root to fill passes, that the TIP TIG unique weld characteristic discussed in the Welding Process section, make TIP TIG the easiest to use process. This process reduces all position welder skill requirements.
In contrast to Pulsed MIG, GTAW and Flux Cored, TIP TIG with it’s weld travel rate capability combined with EN polarity, enable on any metals the lowest possible welded part heat input, providing the smallest possible weld HAZ, which should always the best possible metallurgical properties.
Next time your weld shop utilizes two arc weld processes for one code weld application, such as TIG and Flux Cored, or TIG and MIG, remember if TIP TIG was utilized, one power source, one weld wire, one gas, one welder qualification procedure, and one weld procedure, with two common weld settings. In contrast to the DC TIG process, TIP TIG with all position welds is as cost effective as Pulsed MIG. With TIP TIG code quality welds, there are no weld application size, thickness or metal restrictions.
As you traverse this site, apart from examining the weld quality, view the weld pictures or videos from a weld fume perspective. If the parts welded have contaminates on the surface such as forming lubricants, then of course fumes will occur. If however TIP TIG is used on clean parts, in contrast to MIG and flux cored, TIP TIG will enable the lowest possible weld fumes. And with most clean weld applications, exhaust equipment will typically not be required.
Each hour on average, one TIP TIG welder will do the welds produced by 3 to 4 DC TIG welders. With all position welds, TIP TIG will provide similar weld speeds as pulsed MIG. Don’t forget weld rejects, weld rework, weld grinding, weld cleaning, and part distortion also influence weld costs, TIP TIG should eliminate those issues. For the most comprehensive, technical process data on TIP TIG versus common arc weld processes link up with “All Welding Processes” above.
In the METALS section view the unique TIP TIG benefits attained
The solution to consistently attain optimum code weld & part quality on all steels, alloy steels and alloys, is use an easy to use, semi-automated arc weld process, that can enable the highest weld quality while producing the lowest welded part heat input.
The unique TIP TIG combination that provides the highest weld quality with the lowest possible welded part heat, and also the widest possible weld joules range, provides weld / part properties not possible from TIG – MIG or FCAW.
The weld heat related requirements of most metals will be eliminated or greatly reduced with TIP TIG. This should shock any weld engineer or metallurgist that TIP TIG in contrast to any other manual arc process, should provide on average, a 35 to 65% reduction in weld joules.
Depending on the the weld / clad application and the code quality requirements, weld porosity can be a minor or major weld issue.
There are many things that contribute to the formation of weld porosity, however there is one fact that all weld shops should consider. With all metals, TIP TIG enables not only the highest weld energy but also lowest weld oxidation potential. This is influenced by the TIP TIG high arc temperature, the unique small fluid weld droplet transfer, the TIP TIG plasma coverage over the weld surface, the weld speeds and EN polarity and the use of inert argon. Extensive information in the Metals Section.
My TIP TIG - Manual MIG - Robot MIG - Gas Shielded Flux Cored, Weld Process Controls & Best Weld Practice, Self Teaching and Training Resources
In the 1980's, I first started to discuss the importance of Weld Process Controls and Best Weld Practices, and their influence especially on the Semi-automated weld processes, MIG and Flux Cored. For those that purchased my programs, or attended my work shops, a segment of my 1980's Weld Clock Method and MIG Made Simple program is shown here. Without weld process controls and best weld practices we have what many weld shops have, experienced welders "playing around" with their wire feed and voltage controls, and each welder using what the believe was the best weld techniques and practices, it's been this way for more than 60 years. TIP TIG is also a process that requires continuous wire feed and amp settings, something no welder will have experienced. The question for the weld industry is, do they continue this approach to weld quality and productivity for another sixty years, or will some decision maker who believes in Process Ownership Responsibility, step up to the plate, and finally provide their weld shop and from office employee with one of my TIP TIG - Manual MIG - Robot MIG and Gas Shielded Flux Cored Self teach / Training programs. Info here.My Process Control Resources
2010, I have spent the last decades studying TIP TIG, and and last two years putting together a TIP TIG Self teach / Training program. What is unique about this program, is it addresses both the weld shop and front office TIP TIG weld process ownership requirements.
- The WELD SHOP will want to avoid having welders “playing around” with process, so the unique TIP TIG weld settings for all applications are provided. TIP TIG requires careful attention to the torch adjustments which are also provided. This process also has specific TIP TIG best weld practices that apply to any welds.
- The FRONT OFFICE should want to be aware what weld applications will benefit from using TIP TIG. How optimum mechanical or corrosion properties can be easily attained on all metals. Front office personnel should want to know why on any steels or alloys, they will likely not have to budget for weld rejects, distortion, cleaning, or rework. The front office should also be aware of why preheat, inter pass or post heat night be reduced or eliminated. Perhaps management would like to know why all position welder skills and welder training times are dramatically reduced. Also how stainless tanks may be welded without the need for a purge gas, or why titanium can be welded without a gas trail shield. The office should be aware of the COST productivity and quality differences, between TIP TIG, Pulsed MIG, Flux Cored and Hot Wire TIG. And what front office will not want to be aware of why exhaust equipment may not be required when welding chrome alloys
It’s 2020, and first I appreciate your visit to this site. Soon I will have been in this industry for almost 60 years. In the 13 countries, and 1000 plus weld shops that I assisted with weld problems, in over 90 % of the companies, I watched MIG and flux cored welders “playing around” with the two simple controls on their equipment. I saw the purchase of useless MIG gas mixes, metal cored wires and costly electronic MIG equipment, that in reality caused more process issues than it resolved. I talked to the front office weld decision makers who lacked the process expertise or inclination to take ownership of the weld shop processes, they believed that their job was to bring in the local sales rep to assist with the weld problems. In these weld shops, I would resolve the weld issues and then provide both the weld shop and front office personnel with my unique, MIG – Flux Cored Process Control – Best Practice Training programs. These are programs not taught at Community Colleges or taught at Universities that educate engineers.