What is TIP TIG? TIP TIG is the EVOLUTION of Traditional TIG.
The Worlds First Fully Functional Semi-Automatic Manual HOTWIRE TIG
Process.
TIP TIG WON AN AWARD FOR THE BEST WELD INNOVATION AT THE 2008
ESSEN WELD SHOW.
What is the TIP TIG process? The TIP TIG process is a Globally
Patented dynamic TIG process. The process combines our wire feed
technology which creates a vibratory effect on the wire in addition
to applying a hotwire current to the filler metal prior to entering
the weld puddle.
The vibratory effect is created by a linear forward/backward
mechanical motion created by the custom wire feeder system
The Hotwire current is created by a secondary power source
within the Tip Tig unit.
13 Conventional GTAW power supply No foot petal required
Standard MIG wire 100% Argon How is the TIP TIG Process
Operated
TIPTIG Hotwire 18 Water Cooled Torch Standard Length 14ft
(4.25m) Duty cycle 400A/100% Part Number # 10002460 TIPTIG Hotwire
18 Water Cooled Torch 2 Button Momentary Action Up Function = Arc
On / Arc Off Down Function = Wire On / Wire Off
Standard TIP TIG Package
Selecting a Power Source to use with TIP TIG The TIP TIG
Process requires a conventional TIG Power Supply. TIP TIG 500DC
(Recommended for TIP TIG Automation Applications) Miller Maxstar
350 and Dynasty 350 (Recommended for Manual Applications) Miller
Maxstar / Dynasty 350 350 AMP TIP TIG DC 500 500 AMP
TIP TIG Portable Suitcase Feeder Package
TIP TIG AUTOMATION TIP TIG TRACTOR TIP TIG ORBITAL All of our
automation systems incorporate the use of our patented wire feed
technology Simple to use touch screen programmable interface Arc
Voltage Control (AVC) Auto Electrode Adjustment (AEA) for setting
the tungsten to work distance.
TiP TiG Automated Work Station with AVC control
TIP TIG Robotic Solutions
Total Benefit from TIP TIG? Highest deposition rates for any
TIG process available on the market. No Slag, No Inter pass
cleaning = increased Arc on time and weld quality Lowest possible
heat input of any weld process resulting in lowest HAZ and
significantly reduced distortion. Increased corrosion property
retention on all corrosion resistant alloys. Highest quality with
the best Metallurgical and Mechanical properties on all alloys.
Simple to Learn, Simple to Use, Simple to Teach.
Values of Heat Input with TIP TIG Joules Heat Input Formula
(Voltage x Amperage x 60 / Travel Speed IPM) Typical MIG Heat Input
25 x 250 x 60 / 16 = 23.437 Kj Typical TIP TIG Heat Input 13 x 250
x 60 / 16 = 12.1875 Kj Conventional TIG Heat Input 13 x 200 x 60 /
8 = 19.500 Kj
In Comparison to Regular TIG TIP TIGs wire feed speeds and
amperage are constant and stable, allowing for the greatest control
of the weld process. Improved weld uniformity and repeatability
Weld wire is consistently directed to the sweet spot of the arc in
any position. Reduced skill level required for all position, all
alloy welding.
TIP TIG Stainless Pipe Fill Pass. Manual. Vert Up. 0.035 Wire.
Untouched weld on Stainless Steel Pipe. Note tight, manual weave,
stringers may also be welded. Examine the weld energy, side wall
wetting, small HAZ, weld continuity and lack of oxide reaction. On
pipe, TIP TIG typically one to three hundred percent faster than
regular TIG and expect manual welds that looks as good as orbital
welds.
Thin guage I mm Duplex. Automated TIP TIG weld, 30 inch/min.
Note small HAZ and weld uniformity quality with sluggish duplex.
TIP TIG Manual weld benefits 14 guage (0.080) 2 mm and thicker. TIP
TIG Automation, depending on fit down to 0.035 (1mm).
Inconel 625 on Carbon Steel
The only tool used on this Inconel TIP TIG pipe job was a tooth
size stainless brush. This whole project including the pipe to
flange joints was a 100% x-ray with zero percent weld rework. TIP
TIG was used from the root pass to the cap. The fill pass welds
were typically 200 to 300% faster than regular TIG 18 inch Diameter
Inconel pipe. TIP TIG welds.
TIP TIG Customers Westinghouse Exxon Mobil GE Siemans Emerson
Bechtel UA PipeFitters / NA WSI Aquilex Caterpillar / Solar
Turbines AIP Aerospace 600 + machine sold throughout North America
Spirit Aerospace AIP Aerospace Coast Composite Newport News
Shipyard CM2H Hill Doyon Associated CNOOC JH Kelley Mechanical
Kiewit Offshore Los Alamos National Laboratory Shaw AREVA MOX
Services, LLC
UA Leads the Way with Advanced Welding Process Over the past
year, the UA has invested in equipment and specialized training
classes to be on the leading edge of a newly developed welding
process known as Tip-Tig. Tip-Tig is a semi- automatic hot wire gas
tungsten arc welding process. For the first time since 1941, the
standard manual GTAW welding process has taken a giant leap forward
allowing our UA welders to perform at the highest of levels in this
new Tig welding process. Using this new technology, UA members and
our signatory contractors will have a significant advantage in the
pipe welding industry. With the high quality of welding and up to
600% increase in production, this new process will allow the UA
welder and contractor to be successful for many years to come. The
newly developed UA Tip-Tig Welder Training Course was first
introduced at the 2011 Instructor Training Program in Ann Arbor,
Michigan. During the week of classes, the course instructors were
pleased to talk and interact with approximately 600 visitors that
showed up to see the new process. Among the visitors were General
President William Hite, Assistant General President Steve Kelly and
UA local union members ranging from business managers to field
personnel. Numerous industry representatives from organizations
such as Bechtel, Pioneer Pipe and Duke Energy were extremely
interested in the new welding system and its applications in large
scale construction projects. Many of the visitors were able to
receive some hands on training. At the end of the week we were able
to show all the visitors a new process that will have great
benefits for the United Association members and contractors. Since
that time interest has grown considerably in the application of the
new process. We recently received a mailing from Bechtel that
included an excerpt from one of their technology bulletins that
talked about the first job site use of the TIP-TIG welding process.
In southeastern Washington State, Bechtel National, Inc. is
designing, constructing and commissioning the worlds largest
radioactive waste treatment plant for the U.S. Department of
Energy. When complete, the Hanford Tank Waste Treatment and
Immobilization Plant will process and stabilize 56 million gallons
of radioactive and chemical waste currently stored at the Hanford
Site. Although the process was used by a subcontractor to Bechtel,
its currently being evaluated for use on Bechtels LNG projects
around the world.
In southeastern Washington state, Bechtel National, Inc. is
designing, constructing and commissioning the worlds largest
radioactive waste treatment plant for the U.S. Department of Energy
(DOE). When complete, the Hanford Tank Waste Treatment and
Immobilization Plant (WTP) will process and stabilize 56 million
gallons of radioactive and chemical waste currently stored at the
Hanford Site. Bechtel's subcontractor Intermech. Inc. is using the
new TIP TIG process to weld it's 42 - 60 inch diameter stainless
piping, both in their shop and in the field. The pipe is utilized
as an HVAC duct in a nuclear air-duct application. BCOI Welding and
NDE Services have recognized the potential of the Tip Tig GTAW
process and are evaluating the application of this process. Bechtel
Welding and NDE Services will be working with the project to
utilize available equipment in order to evaluate the processes
potential and perform R&D. At this present time Bechtel has a
number of projects which will require installation of large
quantities of large bore stainless steel piping. Based on
preliminary evolution the Tip Tig GTAW and equipment may add value
by increasing productivity, maintaining or perhaps increasing the
quality while reducing hexavalent chromium exposure to craft
welders.
CNOOC - Chinese National Offshore Oil Company The China
National Offshore Oil Corporation, (CNOOC Ltd) is China's largest
offshore oil and gas producer. During 2010, CNOOC successfully
expanded its business to South America and the Middle East. In
2010, CNOOC revenue rose 74% while its net profit rose to $8.03
billion US dollars. 2011. CNOOC had weld concerns in China with the
qualification of costly, manual and automated offshore, barge pipe
welds. The welds were made on ID, Inconel clad sub sea pipe joints.
The 5G pipe welds were made on a ship that fed pipe from an oil
platform to land. This sub sea pipe line was approx. 20 miles in
length. For the ID, Inconel clad pipe welds, CNOOC engineers had
tried regular TIG and the Pulsed MIG process. The engineers had
access to the most costly, sophisticated global weld equipment
available. The weld equipment and processes evaluated could not
consistently attain the clad weld quality on the pipe ends. With
the TIG clad welds there was excess heat issues and the 5 G TIG
welds were simply too slow. The pulsed MIG process was incapable of
meeting the 100% x-ray pipe welds and ID Inconel clad welds. As
zero weld rework was a requirement for this project and regular
processes were incapable of meeting the weld quality - productivity
goals, CNOOC turned to TIP TIG USA for the manual and automated
weld solutions. With two weeks of testing at the TIP TIG USA
facility, TIP TIG proved it could consistently achieve the desired
100% X-Ray, zero percent manual - auto weld quality and production
requirements for the 5G welds. CNOOC quickly placed an order to TIP
TIG USA for it's manual- automated TIP TIG weld equipment. TIP TIG
provided training, the weld procedures and the manual - automated
equipment for this multi-million dollar project.
Tip Tig .. The Solutionfor All Material Types on Plate and
Piping Inconel 625 Carbon Steel Stainless Steel P91
WELDING PROCEDURE QUALIFICATION: Question: If a manufacturer or
contractor has a WPS that was qualified by manually welding the
test coupon and using filler, is it necessary to requalify the WPS
when using semi- automatic welding such as TiP TiG? Reply: When you
qualify the WPS, you are demonstrating the properties of the weld,
and the weld does not know if it was made with filler metal added
by hand or with filler metal added by a machine, so the properties
of the weld are unaffected by the method by which the filler metal
is added. Following Section IX rules, Table QW-256 identifies
QW-410.25 (which addresses the type of welding: manual,
semiautomatic, machine and automatic welding) as a nonessential
variable for GTAW. When a variable is nonessential, that does not
mean that you can ignore it; nonessential means that the variable
has to be addressed in the WPS -- but it does not have to be
qualified. That means that when you want to start using TiP TiG,
you have to revise the WPS to allow semi-automatic welding, but you
do not have to requalify the WPS. Since semi-automatic welding
requires the use of a wire feeder, the wire size and the wire feed
speed rate (ipm) must also be specified in the WPS.
WELDER QUALIFICATION: Question: Is a welder who is qualified to
use the GTAW process while adding filler metal by hand also
qualified to welding using semi-automatic GTAW? Reply: Yes. Table
QW-356 provides the qualification variables for welders using the
GTAW process. Note the following: 1) The title of QW-356 is
Essential Variables for Manual and Semi-automatic Gas Tungsten- Arc
Welding (GTAW) and 2) There is no other variable in that table
regarding the type (see above) of welding. Using TiP TiG is not the
same as adding filler metal by hand. Welders should practice using
the equipment until they can make welds that exhibit full
penetration on roots and good fusion between passes. While
requalification using TiP TiG is not a requirement, welding a test
coupon and doing some bend tests to verify welder skill is
recommended. THE BOTTOM LINE: When you switch over TiP TiG, you do
not have to requalify your WPS or welder to use TiP TiG; however,
your WPS needs to be modified to allow the use of semi- automatic
welding and to specify the correct wire size and filler metal feed
speed, and the welder should receive some training with TiP TiG
before being turned loose.
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