2019.. TIP TIG Welding Em Craig.

All you have to do is compare the features of each process and see how this process is suited to all industries.

The most important attribute of a weld is weld fusion potential. In contrast to GTA – GMA and FCA, TIP TIG enables the highest arc temperatures and  eliminates weld fusion concerns with sluggish alloys. The increased weld fluidity from TIP TIG, enables groove dimensions reductions of 25  to 50%, dramatically reducing weld labor and consumables costs.

Many weld shop will use two processes for an application, one for the root and another for the fill. Unlike GTA TIP TIG is not limited in weld application size or part thickness, TIP TIG,  one gas, one weld wire, one procedure and typically no  more than two common weld settings for any welds on all metals.

TIP TIG is  providing the highest weld energy in an inert atmosphere providing the lowest possible weld impurities and porosity, the lowest weld oxidation thus producing the cleanest welds.

Aerospace
Nuclear
Food & Beverage
Defense
Mining
Power Generation
Offshore & Petrochemical
Medical
Heat Exchanger Manufacturing
Ship Building & Navy
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TIP TIP  semi-automated, increased deposition (increased weld speed) capability with EN polarity and lower volts than GMA and FCA provides the lowest possible weld heat input, eliminating concerns for oxidation effecting corrosion, distortion, cracks, stresses.  A correct  TIP TIG weld will produce the smallest weld HAZ optimizing metallurgical results. This process will also reduce or eliminate  pre-heat, inter-pass temp, or post-heat requirements.

What weld shop will not benefit when there is no weld spatter, no cleaning, no from the manual or automated TIP TIG process that as a result of travel rate, low volts, EN polarity and an inert gas achieves  the lowest least possible weld fumes often eliminating the need for EXHAUST equipment.

TIP TIG like GMAW and flux cored is a Semi-automated process, however it provides never before attained weld benefits in contrast to all arc weld processes.

As mentioned manual or automated TIP TIG, in contrast to GTAW, GMA and Gas Shielded Flux Cored, enables per-application, higher arc weld energy with superior weld wetting. Think about your potential weld re-work costs. No more lack of fusion,  which is especially important  with all position welds on common sluggish alloys like Stainless, Duplex and Inconel.

Pulsed MIG and Flux Cored on steels utilize reactive gas mixes, while TIP TIG only requires  inert argon. With steel welds.  TIP TIG will always ensure with  manual or automated welds and clad  weld applications, the lowest possible porosity.

Those weld shops that use Pulsed MIG, GTAW, SMAW and Gas Shielded Flux Cored on all position pipe / plate welds, will when using TIP TIG find from the root to fill passes, that the TIP TIG unique weld characteristic  that are discussed in the TIP TIG Vs GTAW Welding Process section, make TIP TIG  the easiest to use all position process that also enables superior weld quality. 

Its this simple. In contrast to Pulsed MIG, GTAW and Gas Shielded Flux Cored, TIP TIG will enable typically a 30  to 60 % reduction in weld joules.

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In this highly completive global industry when the key weld decision make utilizes TWO arc weld processes such as GTA – GMA- SMAW – FCA for a code weld application, first think about the different procedures, welder skills and practices that the weld shop imposes on itself. In contrast, if TIP TIG is utilized, the shop would use; [A] One power source. [B] One weld wire. [C] One gas. [D] One welder qualification  procedure. [E] One skill set and one set of best weld practices, [F]  One simple weld procedure. [G] Typically no more than two common weld settings used for most welds. Remember 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 GMAW and FCAW, TIP TIG should always enable the lowest  possible weld fumes. And with  most clean weld applications, exhaust equipment is typically not required.

Each hour on average, one TIP TIG welder will do the welds produced by 3 to 4 DC GTAW welders. With all position welds, TIP TIG will provide similar weld speeds or times as pulsed GMAW and FCA welds. Don’t forget weld rejects, weld rework, weld grinding, weld cleaning, and part distortion also influence weld costs, and 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.  Those of you that want to attain my TIP TIG self teach / training program, visit the TRAINING section.

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 to utilize the easy to use, semi-automated TIP TIG process, that can enable both the highest possible 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 statement should shock any weld engineer or metallurgist. “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. agitated  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 Process section.

Em Craig's 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

2020, I have now spent the last decade studying how TIP TIG compares with other arc weld processes, 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.

  • Any weld shop FRONT OFFICE would want to avoid having  their welders “play around”  with the new TIP TIG process. So for all metals and applications I provided a program that provide  the majority of the unique TIP TIG weld settings. TIP TIG requires careful attention to the torch adjustments which are also provided. This process also has specific  again unique TIP TIG best weld practices that apply to any welds. These to are provided.

     

  • The FRONT OFFICE  personnel 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 with TIP TIG not likely to have to budget for weld rejects, part distortion, grinding, cleaning, or rework.

     

  • The FRONT OFFICE personnel should also be aware of why preheat, inter pass or post heat night be reduced or eliminated.

     

  • Perhaps the FRONT OFFICE weld decision makers would like to know why all position welder skills and welder training times are dramatically reduced. Or  how with TIP TIG stainless tanks may be welded without the need for a purge gas. Or when welding  Titanium, the TIP TIG welds may be welded without a gas trail shield or fear of costly rejects.
  • The FRONT OFFICE personnel should also be aware of the weld  COST productivity and quality differences, between TIP TIG, Pulsed MIG, Gas Shielded Flux Cored and also the Hot Wire TIG process.

     

  • And what FRONT OFFICE personnel would  not want to be aware of  why exhaust equipment may not be required when welding  chrome alloys, and why they can dramatically reduce future welder  liability health claims from weld personnel working with stainless, duplex, inconel  and other hazardous metals.

EmcIt’s 2020,  and first I appreciate your visit to my long winded site, you likely have figured out I don’t have a life. I have been in this industry for decades and 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 weld  issues than it resolved. I watched the automotive industry purchase robots and the managers and engineers thought the robots would compensate for their lack of weld process ownership ability. I traversed many weld shop floors in aerospace and defense companies, and rarely found someone in the front office who understood the two simple controls on a MIG power source. It’s unfortunate that many front office weld decision makers lacked the  expertise or inclination  to take ownership of their weld  shop processes. Its also a sad comment that many weld decision makers to resolve their weld issues arose,  they would  bring in the local sales rep. with a degree in fine arts to assist with their weld problems. In the weld shops I visited, I would quickly resolve the companies weld issues and then insist that I provide both the weld shop and front office personnel with one of my MIG – Flux Cored  – TIP TIG Weld Process Control – Best Practice Training Programs. I believe this expertise which is not  not taught at Community Colleges or at Universities that educate engineers, has for decades been the missing link of most global weld shops. Thanks for being here. Em. Craig.