TIP TIG Welding Em Craig.
All industries benefit from the unique TIP TIG weld attributes.
All weld applications benefit from a weld process such as TIP TIG which enables the highest arc temperatures and eliminates weld fusion and sluggish alloy concerns. The increases arc energy from TIP TIG also enables Vee groove dimensions reductions 25 – 50% that also dramatically reduce weld labor and consumables costs.
What weld shop in any industry won’t benefit in that they can use 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 on all metals.
TIP TIG while providing the highest weld energy, provides that energy in an inert atmosphere providing the lowest possible weld impurities and porosity, the lowest weld oxidation thus producing the cleanest welds.
TIP TIP is a unique semi-automated arc weld process in that it will eliminate concerns for distortion, weld cracks, weld stresses. The reason is simple increases weld speeds with EN polarity. TIP TIG should create welds that produce the smallest weld HAZ eliminating, corrosion, mechanical property concerns. This process will also reduce or eliminate pre-heat, interpass temp, or post heat requirements.
What weld shop will not benefit when there is no weld spatter, cleaning, grinding from a manual or automated arc weld process that achieves the lowest least possible weld fumes often eliminating the need foe EXHAUST equipment.
In the Weld Process comparison section you will find why this process is unique, and comparisons between TIP TIG Vs Pulsed MIG - GTAW - Flux Cored, and the Hot Wire TIG process.
Manual or automated TIP TIG, in contrast to GTAW, Pulsed MIG and Gas Shielded Flux Cored, enables much higher arc weld energy with superior weld wetting that leads to superior all position weld fusion, and this also benefits sluggish alloys like Stainless, Duplex and Inconels.
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.
What used to be difficult is now made simple. Those that use Pulsed MIG, GTAW and Gas Shielded Flux Cored on 5 – 6G pipe 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 Welding Process section, make TIP TIG the easiest to use all position process.
In contrast to Pulsed MIG, GTAW and Gas Shields Flux Cored, TIP TIG with it’s TIG weld travel rate capability combined with EN polarity, enable on any metals the lowest possible welded part heat input, which can produce welds with the smallest possible weld HAZ, that should always enable the best possible metallurgical properties.
Next time your weld shop utilizes two arc weld processes for a code weld application, processes such as GTAW and Flux Cored, or GTAW and Pulsed MIG, remember if TIP TIG was utilized, the shop would use one power source, one weld wire, one gas, with one welder qualification procedure, and one simple weld procedure, with typically no more than two common weld settings. In contrast to the DC GTAW process, TIP TIG with “all position” welds can be as cost effective as Pulsed MIG or flux cored. Important. 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.
It’s 2020, and first I appreciate your visit to this long winded site. You likely have figured out I don’t have a life. 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 weld issues than it resolved. I watched the apathetic automotive industry purchase robots and the managers and engineers sat back and thought the robots would compensate for their complete 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 Too many front office weld decision makers lacked the expertise or inclination to take ownership of their weld shop processes. Its a sad comment that in reality they would too often believe that when weld issues arose, their job was to bring in the local sales rep to assist with the 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.