Technology

The TIP TIG
Welding Process

Dynamic Wire Feeding

TIP TIG is a unique hot wire TIG welding technique for manual, automated, bore cladding, and orbital applications. It works with all metal types, just like traditional TIG.

See It in Action

Watch How TIP TIG Works

See the dynamic wire feed in motion. The oscillating wire agitates the weld pool for porosity-free, X-ray quality results.

How It Works

Hot Wire TIG —
Reinvented

A separate low-voltage source heats the filler wire close to melting point. It flows smoothly into the weld pool for much higher deposition rates.

Enhanced Wetting The heated wire improves weld pool wetting instead of cooling it. Unlike cold wire TIG.
No Secondary Arc The low voltage prevents arcing between wire and base metal. The tungsten maintains the primary arc. A separate power source heats the wire.
Easy to Learn Works manually in all positions. Easy to learn. Pays for itself right away.
8.8 4.0 lbs/hr kg/hr
Peak Deposition Rate
vs. 0.7 lbs/hr conventional TIG vs. 0.3 kg/hr conventional TIG
TIG
TIP TIG
Wire Dynamics

Four-Drive Roll
Oscillation System

Four drive rolls feed and oscillate the filler wire through a mechanized drive plate. Hot wire plus mechanical vibration delivers maximum welding energy at minimal heat input.

Weld Pool Agitation

Mechanical vibration stirs the weld pool and breaks surface tension, improving fusion.

Stress Relief

Dynamic wire oscillation relieves residual stresses during welding, improving joint integrity.

Reduced Porosity

Pool agitation minimizes pore defects. Especially useful on sluggish alloys like stainless steel and duplex.

Higher Deposition Rates

A more fluid weld pool allows higher wire deposition and increased welding current.

Lower Heat Input

Reduced heat input lowers metal distortion and preserves corrosion-resistant material properties.

All-Position Capability

Operates in all welding positions with consistent quality and straightforward technique.

Performance

Deposition Rate
Comparison

2-inch Schedule 80S stainless steel pipe (DN50, 60.3 mm OD, 5.54 mm wall), 5G position. TIP TIG delivers over 12x the deposition rate of conventional TIG.

All values measured in lbs/hr under identical test conditions. All values measured in kg/hr under identical test conditions.
TIG
0.7 0.3
TIG Cold Wire
2.2 1
TIG Hot Wire
3.3 1.5
TIP TIG
8.8 4
lbs/hr kg/hr
Process Comparison

TIP TIG vs. Other
Welding Processes

Compare 15 key characteristics. TIP TIG outperforms conventional welding methods across the board.

Characteristic TIP TIGMIGTIGFCAWStick
Deposition Rate ★★★ ★★★ ★★★ ★★★ ★★★
Weld Speed ★★★ ★★★ ★★★ ★★★ ★★★
Heat Input ★★★ ★★★ ★★★ ★★★ ★★★
Weld Distortion ★★★ ★★★ ★★★ ★★★ ★★★
Skill Level Requirement ★★★ ★★★ ★★★ ★★★ ★★★
Fusion Capability ★★★ ★★★ ★★★ ★★★ ★★★
Consumable Costs ★★★ ★★★ ★★★ ★★★ ★★★
Fusion Quality ★★★ ★★★ ★★★ ★★★ ★★★
Porosity / Inclusions ★★★ ★★★ ★★★ ★★★ ★★★
Start-Stop Requirements ★★★ ★★★ ★★★ ★★★ ★★★
Weld Fume ★★★ ★★★ ★★★ ★★★ ★★★
Spatter Generation ★★★ ★★★ ★★★ ★★★ ★★★
All-Position Capability ★★★ ★★★ ★★★ ★★★ ★★★
Joint Fit-Up Tolerance ★★★ ★★★ ★★★ ★★★ ★★★
Overall Performance ★★★ ★★★ ★★★ ★★★ ★★★

MIG Challenges

  • Lack of fusion risks
  • Poor weld tie-ins
  • Porosity concerns
  • Poor all-position capability
  • Wire stick-out issues

TIG Challenges

  • Lowest deposition rate
  • Lowest welding speeds
  • High heat input
  • Significant distortion
  • Highest skill requirement

Stick Challenges

  • Low deposition rate
  • Fusion concerns
  • Slag inclusion risk
  • High porosity potential
  • Start-stop defects

FCAW Challenges

  • Slag inclusion risk
  • Fusion concerns
  • High porosity potential
  • Spatter concerns
  • Fume generation
23.4 0.92
MIG
19.3 0.76
TIG
11.9 0.47
TIP TIG
kJ/in kJ/mm
Heat Input

Lowest Heat Input
of Any Process

At just 11.9 kJ/in, TIP TIG delivers nearly half the heat input of MIG welding At just 0.47 kJ/mm, TIP TIG delivers nearly half the heat input of MIG welding and much less than conventional TIG. Less distortion. Better material properties. Higher weld quality.

Calculated per ASME IX 2017
H =
V × A × 60 S × 1000
H = Heat Input (kJ/inkJ/mm) V = Voltage A = Amperage S = Travel Speed (in/minmm/min)
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