Quarterly Publication Rs. 20

January 2019 Weld 17 Bead 4

IWS 2k18

AROUND IWS

IWS AWARDS 2018

GET-TOGETHER MEETING WITH

OTHER PROFESSIONAL BODIES

KNOWLEDGE SHARING

SHORT TERM CERTIFICATE COURSE IN

WELDING TECHNOLOGY (Level-1) FOR

PRACTICING WELDERS AT NORTH EAST

INDIA

INTERNATIONAL WELDING SYMPOSIUM

2018 (IWS 2K18) AT MUMBAI

WORKSHOPS AND SEMINARS

COURSES BY SZ

TECHNICAL PAPERS

DEMAGNETISATION OF TUBE ENDS IN

COIL AND PANEL WELDING SHOP – OUR

EXPERIENCE

USE OF TIP-TIG TECHNOLOGY IN

PROCESS EQUIPMENT PLANTS

THE JOURNAL OF

Regn. No. 41817 / 2002

QUARTERLY PUBLICATION

Jan 2019 Weld: 17 Bead: 4

PRESIDENT

SHRI S BISWAS

Immediate Past President

SHRI S GOPINATH

Past President

SHRI A V KRISHNAN

Vice Presidents

SHRI A MARUTHAMUTHU SHRI U D RANE SHRI M P JAIN

Hon. Secretary

SHRI N RAJASEKARAN

Hon. Treasurer

SHRI G RAJENDRAN

Members

Dr K Asokkumar Shri R Subburayalu

Mrs. A Santhakumari Dr. T Senthil Kumar

Shri S Rajendran Dr. K Siva Prasad

Dr G Madhusudan Reddy Dr Shashikantha Karinka

Shri Narain Dharmendra Dr V R Krishnan

Prof. Sunil Pandey Dr G Padmanabham

Shri Basu B K Shri Muneesh Narain

Shri Umesh Agarwal Dr T A Daniel Sagaya Raj

Shri Sandeep Mohan Ubhaykar Shri Uma Shanker G

Shri Amit Agarwal Dr T J Prasadarao

Shri Viral Ashok Shah Shri S N Roy

Shri Easwaran R Prof. V Balasubramanian

Shri Tamboli V B Dr M Kamaraj

EDITORIAL BOARD

Shri R SUBBARAYALU – Editor in Charge Dr. G Madhusudhan Reddy Dr. V. Balasubramanian Mrs. A. Santhakumari Dr. T. Senthilkumar

ASSOCIATE EDITORS Shri Praveen Kumar Lakavat Shri R. Arivalagan

CO-ORDINATORS Shri Sanjay Kadam Shri K Ganesh Kumar Dr. S. Aravindhan

PUBLISHED BY

On Behalf of IWS by

Shri N RAJASEKARAN Hon. Secretary (IWS)

INDIAN WELDING SOCIETY INSTITUTIONS BUILDING, KAILASAPURAM, TIRUCHIRAPPALLI – 620 014

INDIA Websites: www.iws.org.in www.iwsevents.com E mail: hiwsindia@gmail.com

Page 3 of 25

IWS JOURNAL

Sincerely Thanks

IWS JOURNAL

CONGRATULATES

Dr. V R KRISHNAN

THE RECIPIENT OF

M ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT

AWARD 2017

M ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT AWARD 2017

Page 5 of 25

IWS JOURNAL

CONGRATULATES

Mr. V K SHIRGAOKAR

THE RECIPIENT OF

IWS FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT

AWARD 2018

IWS FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT AWARD 2018

IWS JOURNAL

CONGRATULATES

Mr S GOPINATH

THE RECIPIENT OF

IWS MERITORIUS AWARD 2017

IWS MERITORIOUS AWARD 2017

Page 7 of 25

IWS JOURNAL

CONGRATULATES

Mr R EASWARAN

THE RECIPIENT OF

IWS MERITORIUS AWARD 2018

IWS MERITORIOUS AWARD 2018

IWS JOURNAL

CONGRATULATES

Mr RAJESH KUMAR GUPTA

Mr PRATAP K SUPALI & Dr K MOHAN

RECIPIENTS OF

IWS ZONAL MERITORIOUS AWARD 2018

IWS Zonal Meritorious Award 2018

Page 9 of 25

IWS JOURNAL

CONGRATULATES

Mr A V KRISHNAN

Mr V B TAMBOLI

Dr K ASOKKUMAR

Mr G RAJENDRAN

Mr S SINGARAVELU

&

Mr MUNEESH NARAIN

IWS HONORARY FELLOW MEMBERSHIP 2018

RECIPIENTS OF

IWS

HONORARY

FELLOW MEMBERSHIP

2018

GET-TOGETHER MEETING WITH OTHER PROFESSIONAL

BODIES

On October 18, 2019, on the day of

Ayudha Pooja Celebrations, a get-together

meeting with other professional bodies,

viz. IIM, IIW and CSI was conducted at the

Institutional Building, Kailasapuram Township,

Tiruchy by the Southern zone.

Chairman (IWS, SZ) & Chairmen of other professional bodies and host

of senior members from all professional bodies graced the event.

@ CENTRES AND ZONES

IWS AT NORTH EASTERN PART OF THE COUNTRY AGAIN

SHORT TERM CERTIFICATE COURSE IN WELDING TECHNOLOGY (Level-1) FOR

PRACTICING WELDERS AT NORTH EAST INDIA

Continuing its focus on empowering the youths in the north

eastern part of the country, the Northern Zone of the society

through the Guwahati Centre conducted a short term

certificate course in welding technology from October 3, 2018

to October 14, 2018. The event was conducted at IIT,

Guwahati. 18 participants attended the course and got

benefitted. Theoretical input was given in the afternoon

sessions and practicals were conducted in the morning

sessions. On 13th Oct 2018, the students undergone the theory examination and practical examination

on 14th October 2018. Mr. M P Jain, Vice President addressed the participants during the valediction

and distributed the certificates to the qualified welders.

AROUND

Page 11 of 25

INTERNATIONAL WELDING SYMPOSIUM

2018 (IWS 2K18) AT MUMBAI

The International Welding Symposium 2018 (IWS

2K18) was successfully conducted at Mumbai during

27- 29 November 2018 in association with the

Welding Research Institute (WRI), Messe Dusseldorf

India, Messe Essen, DVS and Asian Welding

Federation. Shri Atul Sobti, Chairman & Managing

Director of BHEL Tiruchirappalli, inaugurated the

symposium. Shri Subrata Biswas, President (IWS)

and Director (E, R & D), BHEL presided over the

function. Mr. P K Supali, Vice Chairman, IWS, WZ, welcomed the gathering. Mr. Thomas Schlitt,

Managing Director, Messe Dusseldorf India and Mr. Torben Brinkmann, Head (IEM), Messe Essen

GmbH, Germany offered their felicitations. Mr A

Maruthamuthu, Vice President (IWS) briefed about IWS 2k18.

Mr. N Rajasekaran, Hon. Secretary (IWS) conducted the

proceedings and proposed vote of thanks. Mr. Atul Sobti

released the proceedings and Mr M P Jain, Vice President

received the first copy of the proceedings.

Few of the highlights about IWS 2k18 are as follows.

It is the 8th in the sequel and 5th consecutive event at Mumbai by IWS, WRI, MDI, ME, DVS and

AWF.

Dr. V R Krishnan has been conferred with the M. ISMAIL MEMORIAL LIFE TIME ACHIEVEMENT

AWARD 2017.

Mr. V K Shirgaokar conferred with the FOUNDER PRESIDENT LIFE TIME ACHIEVEMENT AWARD

2018.

Mr. S Gopinath former President (IWS) & former ED, BHEL,

Tiruchy and Mr R Easwaran, former Chairman (Technical

Committee) were awarded with the IWS MERITORIOUS

SERVICES AWARD 2018 & 2017 respectively.

Dr. S Rajakumar of CEMAJOR and Mr. Manish Tak of ARCI

received the Young Technologist Awards for institute and

industry categories respectively.

Mr A V Krishnan, Former President, Mr G Rajendran Hon. Treasurer, Mr Muneesh Narain & Mr V

B Tamboli former vice presidents, Dr. K. Asokkumar, Former Secretary and Mr. S. Singaravelu Vice

Chairman, IWS, SZ were conferred as Fellow Members of IWS.

In total 93 papers were received and 85 were presented including 8 overseas papers.

Participation was from 82 organisations and senior consultants. The participants from major

corporate companies in strategic sectors included BHEL, NTPC, DRDO, EIL, BEML, ISRO, HPCL,

Indian Railways, L&T, ADOR, D&H, etc. in the 2018 edition

252 delegates registered for the event from all categories and 226 attended the event. Free

Delegates from IWS Student forum were allowed to

attend the three-day event.

Mr. D S Honavar delivered the valediction address and

distributed the Young technologist awards and best

paper awards. Mrs. A. Santhakumari, AGM (WRI) &

NGC Member summed up the proceedings. Mr V K

Shirgaokar, former vice president (IWS) presided over

the function. Mr Sanjay Kadam, Hon. Secretary, WZ

welcomed the gathering. Mr G Rajendran, Hon. Treasurer proposed the vote of thanks. Mr. N

Rajasekaran, Hon. Secretary conducted the proceedings.

Page 13 of 25

Page 15 of 25

DEMAGNETISATION OF TUBE ENDS IN COIL AND PANEL WELDING

SHOP – OUR EXPERIENCE

N. Dhanasekaran, N. Rajasekaran* & A. Santhakumari*

ASNT NDT LIII (PT, MT, RT, UT), Consultant & Faculty

* BHEL, Tiruchirappalli, India

ABSTRACT

Qualitative and reliable welding connections are of increasingly greater importance.

Components requiring time-consuming edge and welding preparation and precise welding

sequences, the stated quality is more difficult than ever to achieve. Adding component

magnetism to this quickly makes flawless welding quality, a challenge for every welder to attain.

Magnetism in a component causes the arc to deflect, meaning that it can no longer burn stably

and defect free sidewall fusion can no longer be ensured. With GMAW processes, it also leads to

uneven droplet detachment, which can manifest as spatter on the component or interrupt the

arc in case of strong magnetism. Inadequate welding results and time-consuming finishing work

are the result, and this can be costly. Using the fundamentals of magnetism, ferromagnetic

materials and the consequences of magnetism while welding as a starting point,

demagnetization options which were adopted to solve recent problems during tube to tube butt

weld preparation are presented here. In addition to theoretical considerations, day-to-day use

and application tips for production personnel are primary focus which enable reliable welding.

1.0 INTRODUCTION

Magnetism and magnetic phenomena have been known for a long time. While magnetism was

observable only in magnetic iron ore, one can see it in many natural phenomena and technical

applications today. In terms of Physics, the strength of a magnetic field can be defined by the

magnetic field strength H and the magnetic flux density B (magnetic induction). The higher the

field strength H, higher the flux density B. When H becomes zero, a residual flux density remains.

Residual magnetism is the reason for arc instability during welding, the arc weaves and is

deflected, drops do not evenly detach, sidewall fusion is improper and the welding result is of

poor quality.

2.0 FERROMAGNETIC MATERIALS

Ferromagnetic material is magnetic without the influence of an external field. The reason for this

can be looked at in different ways. While, at the atomic level, electron shells interact via orbital

and spin angular momenta to create a parallel alignment of the atomic magnetic moments

causing magnetisation. Physicist Weiss came up with the idea of interpreting the phenomenon

due to the existence of magnetic domains. Each Weiss domain has all magnetic moments within

it aligned in the same direction and has a neighbour of identical size which points in the opposite

direction. Magnetic fields in semi-finished products made of ferromagnetic materials neutralize

each other in the semi-finished product after production and cooling, as the Weiss domains are

in equilibrium. When producing metal pipe and tube cuttings from a continuously cast semi-

Page 17 of 25

finished product, the Weiss domains are separated from each other and are no longer in

equilibrium. These imbalances influence the arc during welding and it may occur at edge prepared

sidewalls to be welded joint. Magnetic particle testing carried out especially at the edge

preparation ends of pipes and tubes using direct current / half wave DC may also cause

magnetism in the pipe and tube sections.

Ferromagnetic materials which are processed or come into contact with magnets, can easily

become magnetized. Other causes include welding, grinding, bending, machining, deep drawing

and even mechanical vibrations and magnetic particle testing. Depending on the type of material

structure, alloy, this magnetism may be retained in the object. The consequences of residual

magnetism may be desirable, problematic or even very costly. A nut that clings to the end of a

screwdriver is handy. Having two products stick together in welding is an undesirable situation;

this interrupts production and therefore costs time and money.

Unwanted residual magnetism can cause many problems in a production process, such as:

products sticking together in a weld;

a rough surface after welding;

welding impossible or with difficulty;

welds that only penetrate on one side;

metal chips that stick to parts or tools;

detection errors by magnetic sensors;

imperfections and thickness differences;

adherence of extra dirt and dust.

In other words: undesired residual magnetism costs time and money and has a negative impact

on the quality of finished products.

Strength and Effect

Field strength (gauss) Effect

>200 Permanent magnet

20-40 Paperclip sticks

>15 Small metal components stick

>10 Small metal shavings stick

>4 Metal dust sticks

40-50 Interferes with arc welding

0,3-0,6 Field strength of the Earth

Magnetic arc blow can be a serious issue with welding jobs. Arc blow can stop a job dead in its

tracks - no good welds so no progress. This can be a great frustration to welders and result in very

expensive project delays. Arc deflection, or indeed extinction away from the point of welding due

to magnetism, is generally referred to as arc blow. This may result in poor quality welding and

usually occurs if the material being welded has residual magnetism. The effect occurs because of

the interaction between the magnetic field of the welding arc and the field of the residual

magnetism. The effect is most pronounced in ferromagnetic steels and although the magnetism

in the material (measured in air at the end of the tubes) may only be a few tens of gauss, after fit

up, the field becomes concentrated in the gap between the two tubes. In this situation the field

may reach very high value. The effect of the magnetic field depends on the welding process but

a good estimate is to assume that fields greater than 30 gauss will cause problems.

Magnetism is undesirable wherever steel is being welded. Residual magnetism in a component

results in an unstable and deflected arc. The effect may be so great that welding is impossible.

Magnetism in the workpiece causes instability of the arc, uneven droplet detachment, heavy

spatter formation, and uneven sidewall fusion. Inadequate welding results mean considerable

finishing work, loss of time and high additional expenses. Hence demagnetisation reduce

expenses, conserve resources and increase quality through high-quality welding results,

minimising finishing work and reducing material and consumables. The objective of

demagnetization is to reduce the residual magnetism not to exceed 3G.

3.0 EFFECT OF RESIDUAL MAGNETISM DURING ARC WELDING

During welding, high-temperature plasma is created between cathode and anode by the ionized

gas and freely moving charge carriers. The plasma column is infinitely mobile and behaves like an

electrical conductor towards electrical and magnetic fields and it is sensitive to electrical and

magnetic interference. If a critical magnetic flux density B exists in the material to be welded, the

plasma column is attracted or repelled, depending on the polarity. The arc is then deflected,

irrespective of the welding torch position, and behaves unstably. As a result of arc deflection,

energy cannot be applied where it is needed. From the user's point of view, all this leads to

insufficient welding results, a great amount of finishing work and to repair or reject hence lead

to serious losses in quality and economy. Prevailing magnetism affects arc processes differently

depending upon the strength B. At levels of 30 to 50 G, arc deflection already results in the fusion

faces not being adequately melted. Shielding gas coverage is not guaranteed as welding

consumables are being fed in. This results in the formation of pores in the weld pool, which in

turn requires reworking or scrapping. Starting at about 80 G, it becomes nearly impossible to

control the process as well. The result is spatter formation and with strong magnetic fields, arc

interruption, re-ignition and thus defects in the weld seam.

4.0 DEMAGNETISATION IN PRACTICE

Preliminary considerations make it clear that ferromagnetic materials can be demagnetized by

passing current in suitable direction and thus generating an opposing magnetic field or a

decreasing alternating field. Possible variations are available to users in day-to-day work for this

purpose.

Page 19 of 25

Magnetism caused by the mechanical separation of components, edge preparation for welding

or due to grinding processes occurs. The first sign of magnetism is the appearance of furring with

iron filings/powder arranged in the shape of a Christmas tree on a component. This is an

indication to the welder of the risk of arc deflection during the welding process. For high-quality

welding results, demagnetisation is recommended after part/edge preparation and before the

actual welding process.

A tube sample with prevailing magnetism which affects welding is demagnetized by the following

method. Copper cable is wound around the pipe (N turns). Copper cable coiling is done in an area

relevant to the welding process, i.e. near the weld seam to be created. A current I, which after a

certain time changes its direction of flow and also its amplitude to a lower value, is sent through

the windings around the tube. The amplitude of the current is reduced each time it passes

through the cable. As a result of this process, the magnetic field strength B and thus also the

residual magnetism in the material, is reduced to near zero ensuring by field indicator (Gauss

meter). Same effect of reducing current may also be achieved by moving the coil away from the

area of interest (withdrawal method). As a basic principle, however, the greater the number of

turns around the component, the more the residual magnetism is reduced. It is not possible to

make a thumb rule regarding exactly how many number of turns and maximum current to start

demagnetization since it depends on the existing magnetism, the material thickness and the

component length. Approximately 10 to 20 turns and 500 to 600 Amps DC have served the

purpose and the residual magnetism is reduced below comfortable level like less than 3 G.

SUMMARY

Arc deflection caused by magnetism is a known problem in joining technology. Due to its sporadic

occurrence, it is necessary to provide welders with fast and reliable methods in day-to-day work.

Simple demagnetizing technique with available facilities has been tried successfully.

Demagnetising technique is customized for the specific tube butt weld in the production line and

demonstrated for effective usage by production personnel very easily.

Figure 01 Workpiece magnetised » Heavy arc deflection Figure 02 Demagnetised » No arc deflection

Figure 03 Coil Winding

USE OF TIP-TIG TECHNOLOGY IN PROCESS EQUIPMENT PLANTS

Rakesh Choudhary & Mr. Plasch#

Head WAPS, Ador Welding Limited, Pune, India

#TiP-TiG Austria.

ABSTRACT

TIP-TIG welding is a new advanced innovation of the common GTAW Process. This process uses

new, patent-pending technology (TiPTiG), that delivers the highest possible weld energy with

the lowest possible weld heat, all while still being user-friendly.

WHAT IS TIPTIG WELDING?

TiPTiG new welding with a hot wire process that can be used in every industry. It is very simple

to learn, use and simple to teach. This process is so unique that higher travel speed, lower heat

input, reduced cycle time, and an overall better-quality welding advantage can be easily

achieved. The TIP-TIG welding

The TIG weld receptivity for higher weld deposition rates is done by decreasing the speeds for

the weld solidification process and increasing the fluid weld area. This allows for a 100%-400%

increase in TIG wire feed rates, increasing the overall weld deposits. All these attributes like faster

speeds and higher than normal weld energy, increase the resulting TIG weld quality and overall

process productivity.

The process is also slag free and uses the lowest possible heat input of any welding process,

producing a Heat Affected Zone (HAZ), all of which help to reduce distortion and weld stress. It

produces some of the highest quality products with the best metallurgical and mechanical

properties on all alloys, but also increases production up to four times the normal speed. There

is also no inter pass cleaning, creating availability for an increased Arc on time and weld quality.

The TIP TIG process is available in manual and automated capability to attain weld and clad

quality levels way beyond the conventional TIG – Hot – Cold Wire TIG – Pulsed MIG and the Flux

Cored process.

HOW IT WORKS?

A TIP TIG welding system uses a

wire fed GTAW system just like a

typical TIG system, but it’s

distinctive for the vibratory effect

on wire at weld pool which is

achieved by a linear forward and

backward mechanical motion

created by the customised wire

feeder system. The forward and

backward motion of the filler wire creates an oscillation that is then transferred to the weld,

Page 21 of 25

agitating the molten weld pool and ultimately disrupting the surface tension. In addition to this

vibratory effect on the wire, a hotwire current (powered by a secondary power source) is also

applied to the filler metal, prior to entering the weld puddle. Above two pictures describes the

weld finish with Manual GTAW & Manual TIP-TIG process.

BENEFITS OF THE TIPTIG WELDING PROCESS

1. Increased fluidity of the weld pool

2. Greater tolerance to joint fit-up

3. Significantly reduced joint sensitivity

4. Greater ability to accept more wire into the weld pool, result in a higher deposition

5. 4-6 times increased travel times

6. Reduced cycle time and heat input

7. Cleaner welds with agitated weld pool

8. Reduced weld stress with the reduced heat input

APPROVED ALLOYS

TiPTiG welding can work on a wide range of alloys such as carbon steel, stainless steel, duplex

and super duplex stainless steels, Inconel, Titanium, Aluminum, Copper, Nickel, and many others

critical materials like P-91, which are used in process plant production.

HEAT EXCHANGERS

Heat Exchangers are commonly constructed from low Carbon Steel, Copper, Copper-Nickel,

Stainless Steel, Hastelloy, Inconel, or Titanium. There are certainly some unique applications and

challenges associated with the welding of heat exchangers, such as the position and access for

the popular circumferential welding of Tube to sheet welds or the half tube shell welding.

A trained TIP TIG welder can typically weld a 50mm tube in 30 seconds… or less with the highest

quality and lowest heat input. Our typical travel speed for fillet welds will be between 300 to 500

mm/min on most applications. Compared with 80 to 150 mm/ min with conventional GTAW

TiPTiG manual system is a low cost semi-automatic solution to tackle any job by selecting a wide

variety of torches for different applications, with modified 180 deg torch it allows a complete

tube sheet welds without repositioning the wire or

stopping, allowing for defect free welds.

The typical customers in the manufacturing and

repair of various sized heat exchangers are in

power plants, chemical plants, petrochemical

plants, petroleum refineries, natural gas

processing, and sewage treatment.

INCONEL CLADDING

Normally, when you manually clad the end of a pipe

ID with Inconel using Pulsed MIG as shown on the

picture and result is often not so good. However

when we use TIP TIG, the results are visible as shown

on the mentioned pictures.

In the pic TiPTiG cladded Job, TIP TIG Inconel 800

pipe was welded with Inconel 82 wire on 10 inch pipe

3/4 Wall, The TIP TIG weld cycle time for the Inconel

pipe was 40 – 50 minutes, whereas the customer

used to take around 4 hrs with regular TIG. When

your weld process can weld a complex incoloy* pipe

and make the welds look simple, that’s a process that

should be given consideration. With TIP TIG, no

brushing, no grinding, no spatter, no weld rework, no

feeding a wire, no foot control, less skills. Note weld

smoke prep machining lubricants. (*Incoloy refers to

a range of superalloys produced by the Special

Metals Corporation group of companies. They are

mostly nickel-based, and designed for excellent

corrosion resistance as well as strength at high temperatures; there are specific alloys for

resistance to chemical attacks)

DUPLEX STEEL WELDING APPLICATIONS

Application: Adjacent picture is of a very thin

Gage Duplex Boilers With traditional

automated TIG process with cold wire may

result sluggish duplex welds.

The customer typically attained a maximum

Hot Wire TIG weld travel speeds from 12 – 15

inch/min.

Then the customer switched over from Hot

Wire TIG to the TIP TIG process. The TIP TIG weld parameters and speeds were achieved using a

0.035 (1mm) 2205 Duplex wire, with TIP TIG travel speed of 35 inch/min was achieved providing

200% increase in weld travel. The welds had a superior, less sluggish weld bead appearance and

the parts had a dramatic reduction in weld distortion, (note the much smaller HAZ). Also the TIP

TIG process was much more stable and consistent.

TIP TIG produces the cleanest welds from lowest possible oxidation. The welds will have the

lowest possible weld pores and inclusions and the smallest possible weld HAZ.

Page 23 of 25

WELDING OF P-91 MATERIAL

Welding of Grade 91 (9Cr-1Mo-V) chromium-molybdenum steel has presented numerous

challenges since its introduction in the 1970s. The gas tungsten-arc (GTAW) process can produce

welds of high quality; however, manual welding can be expensive and labor intensive, requiring

skilled welders with extreme hand-eye coordination and dexterity. Grade 91 productivity can be

increased in either shop or field fabrication by introducing a semiautomatic high deposition metal

transfer (HDMT) GTAW welding process that combines controlled excitation of wire with a hot

wire addition. This technique is cost effective and can be used for the entire weld from root to

cap while producing high quality welds that industry expects from the GTAW process.

With TiP-TiG weld study, it indicates that semiautomatic HDMT GTAW welding process is capable

of producing toughness values comparable to or exceeding manual GTAW and that the process

provides an attractive alternative for welding P91 root and hot passes or the entire weld from

root to cap. Results of this study indicates that semiautomatic HDMT GTAW welding process is

capable of producing impact values comparable to or exceeding manual GTAWT. The process also

provides an attractive alternative for welding P91 root and hot passes or the entire weld from

root to cap. The semiautomatic HDMT GTAW welding process permits an increase in energy (heat

input), larger weld puddle and increased deposition rate while still providing tempering of the

previously deposited weld beads or layers.

TIPTIG HDMT (HIGH DYNAMIC METAL TRANSFER) FOCUS

TIPTIG HDMT FOCUS is a unique TIPTIG welding process its precision and reliability make the

TIPTIG HDMT FOCUS welding process particularly suitable for automated applications in

combination with linear axles, robots and other guiding systems. Nearly all steels, non-ferrous

metals or galvanized sheets can be welded in one layer with filler material; e.g. CrNi-steels with

a material thickness of up to 10 to 12 mm can be welded in single pass without any Joint

preparation. Some of the welded examples are listed below.

It has also been tested that elimination of backing gas in austenitic stainless steel welds using

high deposition metal transfer gas tungsten-arc welding (HDMTGTAW)

TIPTIG HDMT FOCUS PROCESS

Example:

Material: CrNi 8+8 mm

Weld current: 500 A

Weld speed: 46 cm/min

Wire feed speed: 2,0m/min

Below welded samples details are:

Material: CrNi 10+10 mm

Weld current: 500 A

Weld speed: 32 cm/min

Wire feed speed: 1.8

m/min

TIP TIG REDUCED COSTS BY OVER 60%, WHEN COMPARED WITH CONVENTIONAL TIG PROCESS

TIP TIG Cost Comparison

The following comparison shows the actual savings calculated on a real stainless-steel welding

application comparing conventional TIG and TIP TIG on a pipe application (2″ Sch 80 Stainless) in

the 5G position.

Variable / Results Units Conventional TIG TIP TIG Process

Welding process GTAW GTAW

Wire type ER308L ER308L

Wire size mm 2.4 0.9

Wire deposition

speed mm/min 100 1900

Melt off rate g/h 200 580 (3 times)

Deposition efficiency % 100.00% 100.00%

Deposition rate g/h 200 580 (3 times)

Duty cycle % 100.00% 100.00%

Final deposition rate g/h 200 580 (3 times)

Gas type Argon Argon

Flow rate cfh 30 30

Gas/Wire ratio cf/g 63.05 23.62 (60% Reduction

in gas per gm of wire)

The above data shows, the deposition rates approx. 3 times to standard TIG process which

reduces the production costs by 60%

Page 25 of 25

CONCLUSION

TiPTiG is an innovative TIG process and good alternative to standard gas tungsten-arc (GTAW)

process. Its versatility and simplicity makes the manual welder to give higher output. The

Automated High Deposition Metal Transfer (HDMT) GTAW welding process that combines

controlled excitation of wire with a hot wire addition is gives very promising results to challenging

applications.

Plant equipment manufacturing wherever GTAW is applicable, are possible to be replaced by

TiPTiG process which gives very high output without compromising on quality. The success in P91

welding with TiPTiG, also increases the application possibility in that area.

References

1. Paper on ACHIEVING TOUGHNESS IN P91 WELDS FROM ROOT TO CAP USING SEMIAUTOMATIC HIGH

DEPOSITION METAL TRANSFER (HDMT) GTAW WELDING PROCESS by Charles W. “Pat” Patrick

2. Information from TiP TiG USA

3. Information from TiP TiG International AG