The TIP TIG arc welding process with dynamic wire feeding

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 CharacteristicsTIP TIGTIG (GTAW)Stick (SMAW)Gas-Shielded
Flux-Cored (FCAW)
Pulsed MIG
Deposition Rate83788
Weld Speed83688
Heat Input103576
Weld Distortion104666
Skill Level Requirement92459
Fusion Capability108668
Consumable Costs76539
Fusion Quality109668
Inclusions Porosity/Particulate109347
Start-Stops Requirements99337
Weld Fume99337
Spatter Generation109366
Joint Fit-Up Tolerance74678
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


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 / ResultUnitsConventional TIGTIP TIG
Welding processTIGTIG
Wire typeER308LER308L
Wire size2.4 mm0.9 mm
Wire feed speedm/min0.11.91
Melt off ratekg/h0.220.58
Deposition efficiency%100100
Deposition ratekg/h0.220.58
Duty cycle%100100
Final deposition ratekg/h0.220.58
Gas typeArgonArgon
Flow ratem3/h0.850.85
Gas/Wire ratiom3/kg3.921.48
Gas price€/m322.5922.59
Wire price€/kg2.562.56
Labor and overhead costs€/h100100
Wire purchased per year per station11
Number of welding station11
Welding cost per kg of weld deposited
Wire costs2.562.56
Gas costs88.4933.34
Labor costs460.83173.61
Total costs551.88209.51
Cost savings per kg342.37