The TIP TIG arc welding process is a unique hot wire TIG welding process for automated welding, bore cladding, orbital welding, and aluminum welding that uses our innovative, dynamic wire feed technology. Our system’s benefits will provide the highest quality and deposition rates with the lowest possible heat input. TIP TIG is consistently delivering the most excellent metallurgical results on any alloy. It has also proven to provide the lowest possible hexavalent chrome weld fume emissions, measured as undetectable.
Unlike nearly all other hot wire TIG welding processes, it can be operated manually in all positions and with our automation systems. We deliver a widely recognized benefit of reduced labor costs associated with costly rework and training.
Simply put, it’s simple to use, teach, and learn!
The TIP TIG welding machines are dynamic wire feed TIG systems that create a vibratory force on the welding wire and apply hot wire current to the filler metal before entering the weld puddle. The vibratory effect is created by a sinusoidal mechanical agitation created by the custom wire feeder system. A secondary power source within the TIP TIG welding machine creates the hot wire current.
Take some time to explore the benefits of TIP TIG.
How it works
The mechanical action of the forward and backward motion of the filler wire creates an oscillation transferred into the weld. This agitates the molten weld pool, which then disrupts the surface tension.
The combination of these processes produces the following benefits to the weld:
- Increased fluidity of weld pool
- Greater tolerance to joint fit-up – Significantly reduced joint sensitivity
- Greater ability to accept more wire into the weld pool – Higher deposition
- Increased travel speed 4-6 times faster – Reduced cycle time and heat input
- Agitated weld pool – Cleaner welds
- Reduced heat input – Reduced weld stress
TIP TIG Welding – Root Pass
TIP TIG Welding – Filler Pass
Why we’re different
TIP TIG is the only semi-automatic weld process capable of consistently producing optimum, all-position code quality welds on carbon steels or any alloy applications without concern for weld rework and without fear of the effects of weld heat on the alloys welded.
TIP TIG is the only process capable of delivering the highest possible weld energy (optimum fusion – minimum porosity) with the benefit of providing the lowest possible weld heat. These two benefits are necessary to attain optimum code quality welds and resolve most alloy weld issues with regular TIG and pulsed MIG.
With TIP TIG, the continuously fed weld wire is superimposed by a secondary, high-speed oscillation generated by the four rolls, a mechanized drive plate. The drive plate’s mechanical action generates a vibration that passes through the welding wire into the weld. The vibration agitates the weld pool. A further influence on the TIP TIG weld is the hot wire current, which preheats the welding wire, improving the TIG weld’s wire receptivity. The agitation of the TIP TIG weld and the added weld energy create unique TIG weld dynamics, which slow down the weld solidification. Enabling longer TIG weld fluidity allows more TIP TIG weld wire to be fed into the weld pool. The increase in TIP TIG weld wire enables more weld current, further enlarging the TIG arc plasma and increasing the weld energy. This also reduces arc length sensitivity and improves arc stability.
Comparison of welding processes
On a scale from 0 to 10, with 10 being the best
Weld Characteristics | TIP TIG | TIG (GTAW) | Stick (SMAW) | Gas-Shielded Flux-Cored (FCAW) | Pulsed MIG (GMAW) |
---|---|---|---|---|---|
Deposition Rate | 8 | 3 | 7 | 8 | 8 |
Weld Speed | 8 | 3 | 6 | 8 | 8 |
Heat Input | 10 | 3 | 5 | 7 | 6 |
Weld Distortion | 10 | 4 | 6 | 6 | 6 |
Skill Level Requirement | 9 | 2 | 4 | 5 | 9 |
Fusion Capability | 10 | 8 | 6 | 6 | 8 |
Consumable Costs | 7 | 6 | 5 | 3 | 9 |
Fusion Quality | 10 | 9 | 6 | 6 | 8 |
Inclusions Porosity/Particulate | 10 | 9 | 3 | 4 | 7 |
Start-Stops Requirements | 9 | 9 | 3 | 3 | 7 |
Weld Fume | 9 | 9 | 3 | 3 | 7 |
Spatter Generation | 10 | 9 | 3 | 6 | 6 |
Position | 10 | 8 | 6 | 7 | 6 |
Joint Fit-Up Tolerance | 7 | 4 | 6 | 7 | 8 |
Overall Performance % | 89% | 63% | 48% | 54% | 71% |
When attaining code quality welds, each of these four types of welding processes has more than one Achilles Heel
Traditional TIG
- Lowest weld deposition
- Lowest weld speeds
- High weld heat
- Distortion issues
- Highest skill Level
Stick (SMAW)
- Consumable issues
- Low deposition
- Fusion concerns
- Slag inclusion
- High porosity
- Start-stop issues
- Spatter concerns
Gas Shielded Flux (FCAW)
- Consumable issues
- Slag inclusions
- Fusions concerns
- High porosity
- Spatter concerns
- Wire Stick Out
- Weld Fume concerns
- Process confusion
Pulsed MIG (GMAW)
Pulsed MIG (GMAW)
- Lack of fusion
- Poor weld tie-ins
- Porosity concerns
- Poor all position
- Wire Stick Out
- Process and equipment confusion
Values of heat input with TIP TIG
Heat Input Formular (ASME IX 2017):
Traditional TIG
Heat input = 19.3 kJ/in.
Heat input = 0.76 kJ/mm
Pulsed MIG (GMAW)
Heat input = 23.4 kJ/in.
Heat input = 0.92 kJ/mm
TIP TIG
Heat input = 11.9 kJ/in.
Heat input = 0.47 kJ/mm
Deposition rate
Deposition Rate (lb/h)
Deposition Rate (kg/h)
The actual deposition rate on a stainless steel welding application is compared to conventional TIG, TIG cold wire, TIG hot wire, TIP TIG dynamic wire feed on a 2-inch Schedule 80S pipe application (DN50, Stainless, Outside diameter = 60.3 mm, Wall thickness = 5.54 mm ) in the 5G position.
Welding costs
Total Costs (€)
Actual savings calculated on a real stainless steel welding application comparing conventional TIG and TIP TIG on a pipe application (2″ DN50 SCH 80S Stainless, Outside diameter = 60.3 mm, Wall thickness = 5.54 mm ) in the 5G position.
Variable / Result | Units | Conventional TIG | TIP TIG |
---|---|---|---|
Welding process | TIG | TIG | |
Wire type | ER308L | ER308L | |
Wire size | 2.4 mm | 0.9 mm | |
Wire feed speed | m/min | 0.1 | 1.91 |
Melt off rate | kg/h | 0.22 | 0.58 |
Deposition efficiency | % | 100 | 100 |
Deposition rate | kg/h | 0.22 | 0.58 |
Duty cycle | % | 100 | 100 |
Final deposition rate | kg/h | 0.22 | 0.58 |
Gas type | Argon | Argon | |
Flow rate | m3/h | 0.85 | 0.85 |
Gas/Wire ratio | m3/kg | 3.92 | 1.48 |
Gas price | €/m3 | 22.59 | 22.59 |
Wire price | €/kg | 2.56 | 2.56 |
Labor and overhead costs | €/h | 100 | 100 |
Wire purchased per year per station | 1 | 1 | |
Number of welding station | 1 | 1 | |
Welding cost per kg of weld deposited | |||
Wire costs | € | 2.56 | 2.56 |
Gas costs | € | 88.49 | 33.34 |
Labor costs | € | 460.83 | 173.61 |
Total costs | € | 551.88 | 209.51 |
Cost savings per kg | € | 342.37 |