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Highest clad quality with lowest possible weld heat

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2012 Highest clad quality with Work
lowest possible weld Shop
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Featured
25-Aug-2012

TiP TiG Cladding.

(http://youtu.be/tZyn
02-Jul-2012

TIP TIG USA

commercial

It has to be good news when clad weld quality and production

can be improved.
When weld companies are asked to produce alloy clad welds on
or inside costly, complex applications, with TiP TiG they now
have a weld process that will consistently attain the highest
possible clad weld quality with the lowest possible weld heat.
With the bore clad application shown above, the customer
asked if we could we use TiP TiG in the weld position shown.
Two clad weld layers were required. In the past they had used
MIG and with the TiP TiG process we could attain the desired
clad weld metallurgical properties with a single weld layer. The
clad weld surface would be machined to fifty percent of its
thickness and the remaining weld surface had to match the

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Highest clad quality with lowest possible weld heat Page 2 of 5

chemistry of the inconel wire and be completely defect free. The

clad welds had to be made without any weld cleaning between
the two layers and without any distortion to the parts.

(http://youtu.be/e-EtmxDKVBk)

Tip Tig simplfies clad requirements.

(http://youtu.be/e-EtmxdKVBk)
The regular TIG cladding process would not be suited to the
above automated clad application as the weld heat would be
excessive. The Hot Wire (HW) automated TIG process is always
a cladding candidate, however you would have to purchase very
costly automated Arc Voltage Control equipment and you would
have inferior clad weld quality at lower clad weld speeds. The
automated HW process would also have to be dedicated to this
or similar applications.

You could also try pulsed MIG for the clad welds and within two
or three weld passes watch the welds and part become super
hot. With the pulsed MIG you could also anticipate some lack of
fusion and plenty of porosity and inclusion defects in those
welds.

MIG short circuit

clad welds: To
overcome the weld
heat generated with
pulsed MIG, many
companies will for
clad welds consider
the MIG Short Circuit
(SC) mode. SC is always a poor process choice for any
applications in which sluggish alloys are required to produce
defect free welds. With the SC process there will be extensive
spatter, lack of fusion, porosity and inclusions. It's often a
surprise for weld shops, when they find that the SC weld passes
provide weld heat that is too high for the parts. The high weld
heat is the effect of the SC reverse polarity.

Note: Conventional MIG spray transfer is simply too hot for

cladding and the high energy spray weld pools are especially
not suited for most vertical up and horizontal welds.

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Highest clad quality with lowest possible weld heat Page 3 of 5

Ed created the following patented pulsed MIG clad weld for

Aquilex (WSI). This company uses more than a million pounds
of wire each year cladding more than 70% of the world's water
wall boiler tubes.

Pulsed MIG inconel on water wall boiler tubes.

Pulsed MIG cladding may provide the clad required weld

chemistry but will not attain defect free clad welds.

Pulsed MIG clad welds. Pulsed MIG is fine for manual welds in
which NDT is not applied to the internal weld quality. Pulsed
MIG is a great process for external, boiler water wall panel clad
welds in which the NDT weld quality criteria is typically weld
surface chemistry requirements or visual specifications,
however when the inconel or stainless Pulsed MIG cladding is
subject to machining, X-Rays or UT examination, this process
will likely reveal on many applications that the welds have lack
of weld fusion, weld porosity, small pore inclusions and
inconsistent weld ties-ins. Pulsed MIG clad welds will also
frequently cause distortion and have negative impact on the
parts mechanical properties.

With most clad welds, the two primary objectives are attain the
highest weld quality with the lowest possible weld dilution.

TiP TiG offers unique weld dynamics ideally suited to

most clad weld applications.
TiP TiG can increase TIG weld speeds in the range of 200 to
500% which can dramatically lower the weld joules. TiP TiG
agitate the sluggish alloy welds and adds energy to the TIG
weld pool. The TiP TiG alloy solid wires or metal cored clad

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Highest clad quality with lowest possible weld heat Page 4 of 5

wires will produce welds which will be more fluid than with any
other weld process.

Two TiP TiG inconel clad layers untouched.

(http://youtu.be/rcLCsfeAQOk)
As we know with paint, when you lower the viscosity of paint
it's easier to stroke the paint brush across the surface being
painted. With the added fluidity in the slower solidifying TiP TiG
weld. you can increase both the weld travel and weld weave
speeds which can minimize weld dilution. As the TiP TiG weld
solidification is much slower than TIG, it's easier to maintain the
weld arc, making TiP TiG far less sensitive to arc length
variations than the regular Hot - Cold Wire TIG processes
indicated in the picture below.The unique combination of fluid,
agitated welds with the lowest weld joules makes Tip TiG a
great choice when quality clad weld are required and minimum
weld heat is beneficial.

Hot - Cold wire TIG clad weld info. In contrast to the available
MIG weld modes, the automated Hot Wire TIG process when
used for clad welds provides far superior weld quality, however
this process as noted at this site when used with low to
moderate current and using AV Controls will still be highly
sensitive to many weld variables. That weld sensitivity restricts
the wire feed rates utilized which also limits the weld current
and weld speeds. Often the automated Hot Wire TIG welds will
reveal small pores, inclusions, and occasional lack of weld
fusion subjecting the welds to weld rework and further
machining.
Typical Hot - Cold Wire TIG power plant application.

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Highest clad quality with lowest possible weld heat Page 5 of 5

The arc length sensitivity of Hot Wire cladding process is

increased when the welds are made in the vertical up -
horizontal weld positions which require lower weld current.

View TiP TiG ID clad without Arc Voltage Control.

(http://youtu.be/YduobwDCt2U)

TiP TiG amazing untouched clad - weld quality

(http://youtu.be/4Ta-KLfDoHo)

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