The TIG Welding Process
Fabrication shops use the TIG (Tungsten Inert Gas) welding process when they need superior arc and weld puddle control, allowing operators to create smooth welds with no obvious puddles and a seamless appearance when high-quality welds are paramount. This welding process is also used when operators are working with exotic metals such as stainless steels, duplex, super duplex, inconel, and welds that are subject to rigorous testing requirements. Historically, root pass on critical pipe has required TIG or “defect-free welding” because of the need to deliver high-quality welds. The root pass on pipe serves as the foundation of the subsequent passes (and is often where defects/failures are found on SMAW “Shielded Metal Arc Welding” and GMAW “Gas Tungsten Arc Welding” welds). There are also times when welding open root welds, welds without backing, require TIG welds instead of GMAW (Gas Tungsten Arc Welding) or SMAW () welded roots.
The TIP TIG Welding Process
The TIP TIG welding process combines the precision of TIG welding with innovative enhancements to improve productivity and weld quality. At its core, the process utilizes a non-consumable tungsten electrode to transfer current to the welding arc via a TIG torch. However, TIP TIG introduces a patented hot wire feeding system, setting it apart from conventional TIG techniques.
This system preheats the filler wire to a range of 40-80 amps before it reaches the weld pool. Simultaneously, the TIP TIG wire feeder oscillates the filler metal as it enters the arc. This oscillation disrupts the surface tension of the molten weld pool, allowing for better fusion and increased deposition rates.
Because of TIP TIG’s hot wire and oscillation technology, increased deposition rates with lower heat input are possible, enabling welders to meet the highest visual, mechanical, and chemical quality requirements. This unique capability ensures excellent weld integrity while minimizing distortion and maintaining precise control over heat-affected zones.
The result? A distinct “stacked dime” weld appearance, characterized by consistent, high-quality beads. This combination of precision, efficiency, and aesthetic finish makes TIP TIG an attractive choice for industries demanding superior weld quality, such as aerospace, nuclear, and food-grade manufacturing.
The TIP TIG welding process has become a global welding standard, known for its high-quality welds and ability to reduce overall welding time. TIP TIG was invented in Austria by Siegried Plasch, and the name is derived from the German acronym “Technologie Ingenieur Plasch”, meaning “Technology of Engineer Plasch,” (and TIG, meaning “Tungsten Inert Gas”).
The SWR-TIPTIG
Novarc’s Spool Welding Robot + TIP TIG is a cobot designed for pipe, pressure vessel, and roll welding applications using the GTAW or TIG process. When Novarc’s SWR incorporates the TIG welding process, operators are able to perform the highest quality welds with greater precision, and with speeds 2-3x faster than manual TIG welding. Because of the ease of use of the SWR system, SWR with TIP TIG reduces the skill level required for welding, making it accessible to a wider range of operators, essentially enabling a non TIG welder to perform a TIG quality weld.
The SWR-TIPTIG, provides enhanced speed and precision, allowing fabricators to increase productivity, weld quality and consistency. Reasons fabricators are using the TIP TIG process include:
- Higher deposition rates: A 2.6X increase in weld deposition rate and up to 4 lbs/hour, surpassing conventional TIG systems
- Up to 300 % increase in travel speeds
- Highest quality welds that meet and exceed industry standards for weld quality
- Minimal spatter: cleaner work environment with reduced post-weld cleanup
- Patented TIP TIG Feeding System: Innovative design for impeccable weld quality
Many industries, such as those previously mentioned, as well as shipbuilding, mining, oil & gas, chemical processing and water treatment, are all suffering from the same inherent problems in the fabrication world today: lack of skilled labor and limited productivity of manual labor. A need for productivity without sacrificing weld quality and to deliver “perfect” welds is a huge driver across the board in all of these industries, which is why the TIP TIG welding process continues to grow in popularity.