The TIP TIG welding process

Dynamic Wire Feeding

Exploring the mechanics of TIP TIG

TIP TIG stands out as a distinct hot wire TIG welding technique applicable across manual, automated, bore cladding, and orbital welding contexts. It accommodates all metal types, similar to traditional TIG and other manual welding methodologies.

Upon initial exposure, many immediately draw parallels between TIP TIG, MIG, and TIG processes due to its wire-feeding mechanism resembling MIG. In this method, the wire undergoes electrical heating to its melting point with a low open circuit voltage (OCV), ensuring seamless integration into the molten pool, thus augmenting deposition rates.

Contrary to common assumptions, the wire in TIP TIG doesn’t cool the weld; rather, it enhances the wetting of the weld pool, facilitating optimal weld formation. The deliberately low OCV prevents the formation of a separate arc between the wire and the welded metal, thanks to its proximity to the tungsten tip, which sustains the primary arc. As a result, a distinct power source is utilized to energize the wire.

Distinguishing from the majority of hot wire TIG welding techniques, TIP TIG can be operated manually and in various orientations. Its straightforward learning curve and application make it economically viable for industrial expansion and individual usage.

The details of the TIP TIG wire dynamics

TIP TIG welding excels in delivering maximum welding energy with minimal heat input, ensuring superior fusion and reduced porosity, effectively addressing common challenges encountered when welding alloy metals using standard TIG and MIG methods.

Central to this welding process is its innovative approach to hot wire feeding within the TIG framework. TIP TIG welding machines feature a four-drive roll mechanism that continuously feeds and oscillates the filler wire, orchestrated by a mechanized drive plate.

These drives rapidly oscillate the filler wire back and forth, synergizing with the hot wire feeding mechanism to yield several advantages.

The mechanical action of the drive plate induces vibration in the wire, which transfers into the weld pool, agitating it and disrupting its surface tension. This dynamic mechanical agitation proves particularly beneficial for sluggish alloys like stainless steel and duplex.

By enhancing weld fusion, relieving weld stresses, and minimizing pore defects, TIP TIG’s distinctive approach significantly elevates the quality of welded joints.

Moreover, TIP TIG substantially boosts deposition rates and welding speeds. Accelerated welding speed reduces heat input, curbing metal distortion while preserving the corrosion-resistant properties of susceptible metals.

The combination of weld pool agitation and the hot wire system’s preheating of the filler wire engenders a unique TIG welding dynamic that prolongs weld fluidity, facilitating increased wire deposition and applied welding current.

Weld deposition rate

Deposition Rate (lbs/hr)

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.

Comparison of welding processes

From ★ to ★★★, with ★★★ being the best

Weld CharacteristicsTIP TIGMIGTIGFCAWStick
Deposition rate★★☆★★☆★☆☆★★☆★★☆
Weld speed★★☆★★☆★☆☆★★☆★★☆
Heat input★★★★★☆★☆☆★★☆★☆☆
Weld distortion★★★★★☆★☆☆★★☆★★☆
Skill level requirement★★★★★★★☆☆★★☆★☆☆
Fusion capability★★★★★☆★★☆★★☆★★☆
Consumable costs★★☆★★★★★☆★☆☆★★☆
Fusion quality★★★★★☆★★★★★☆★★☆
Inclusions porosity/particulate★★★★★☆★★★★☆☆★☆☆
Start-stops requirements★★★★★☆★★★★☆☆★☆☆
Weld fume★★★★★☆★★★★☆☆★☆☆
Spatter generation★★★★★☆★★★★★☆★☆☆
Position★★★★★☆★★☆★★☆★★☆
Joint fit-up tolerance★★☆★★☆★☆☆★★☆★★☆
Overall Performance★★★★★☆★★☆★★☆★☆☆

When producing code-quality welds, each of these four welding processes has more than one Achilles’ heel

MIG

⊖ Lack of fusion
⊖ Poor weld tie-ins
⊖ Porosity concerns
⊖ Poor all position
⊖ Wire Stick Out
⊖ Process and equipment confusion

TIG

⊖ Lowest weld deposition
⊖ Lowest weld speeds
⊖ High weld heat
⊖ Distortion issues
⊖ Highest skill level

Stick

⊖ Consumable issues
⊖ Low deposition
⊖ Fusion concerns
⊖ Slag inclusion
⊖ High porosity
⊖ Start-stop issues
⊖ Spatter concerns

FCAW

⊖ Consumable issues
⊖ Slag inclusions
⊖ Fusions concerns
⊖ High porosity
⊖ Spatter concerns
⊖ Wire Stick Out
⊖ Weld Fume concerns
⊖ Process confusion

Values of heat input with TIP TIG

Heat Input Formular (ASME IX 2017):

Heat Input (kJ/in)