The TIP TIG arc welding process

The TIP TIG Arc Welding Process, a New Type of WeldingThe 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 patented wire feed technology. Our system’s benefits will provide the highest quality, highest deposition rates with the lowest possible heat input. TIP TIG is consistently delivering the most excellent metallurgical results on any alloys. 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 patented automation systems. A widely recognized benefit we deliver is the reduction in labor costs associated with costly rework and training.

Simply put, it’s just simple to use, to teach, and to learn!

The TIP TIG welding machines are wire fed 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. The hot wire current is created by a secondary power source within the TIP TIG welding machine.

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 significant benefit of also providing the lowest possible weld heat. These two benefits are necessary to attain consistently 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 patent-pending 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 creates 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 further 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 CharacteristicsTraditional TIG
(GTAW)
Stick (SMAW)Gas Shielded
Flux (FCAW)
Pulsed MIG
(GMAW)
TIP TIG
Deposition Rate37888
Weld Speed36888
Heat Input357610
Weld Distortion466610
Skill Level Requirement24599
Fusion Capability866810
Consumable Costs65397
Fusion Quality966810
Inclusions Porosity/Particulate934710
Start-Stops Requirements93379
Weld Fume93379
Spatter Generation936610
Position867610
Joint Fit-Up Tolerance46787
Overall Performance %63%48%54%71%89%

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)

  • 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):

\begin{align*}
Heat\:input\: [kJ/in.] = \frac{Voltage \times Amperage \times 60}{Travel\:Speed \:[in/min]\times  1000}
\end{align*}

Traditional TIG

\[
Q = \frac{13 \:{V} \times 200 \:{A}  \times 60}{8 \:{in/min} \times  1000}
\]

Heat input = 19.3 kJ/in.
Heat input = 0.76 kJ/mm

Pulsed MIG (GMAW)

\[
Q = \frac{25\:{V} \times 250\:{A}  \times 60}{16 \:{in/min} \times  1000}
\]

Heat input = 23.4 kJ/in.
Heat input = 0.92 kJ/mm

TIP TIG

\[
Q = \frac{13\:{V} \times 250\:{A} \times 60}{16 \:{in/min} \times  1000}
\]

Heat input = 11.9 kJ/in.
Heat input = 0.47 kJ/mm

Deposition rate

Deposition Rate (kg/h)

Actual deposition rate on a real stainless steel welding application comparing conventional TIG, TIG cold wire, TIG hot wire, TIP TIG and TIP TIG – HDMT on a pipe application (2″ DN50 SCH 80S 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
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