The benefits

1. Costs Cut. Profits Boosted.

K-TIG customers typically save 75% to 95% on costs.

Relative to conventional TIG/GTAW welding, productivity gains and savings of more than 90% are typical.

When switching from Plasma Arc Welding (PAW) savings of more than 50% are common and productivity gains of more than 50% are typical.

 

2. Extraordinary Speed.

A welding process with extraordinary speed in thick materials, K-TIG is up to 100x faster than TIG/GTAW.

K-TIG provides order-of-magnitude increases in productivity, with welding speeds up to 100x faster than conventional TIG/GTAW welding.

The K-TIG system performs welds of up to 16mm (5/8 inch) thickness in a single pass. For example, a conventional 6-hour TIG weld in 10 inch, schedule 40 stainless steel pipe is typically completed in less than 3 minutes when using the K-TIG system.

The end result? Productivity up. Costs down. Payback measured in months, not years.

 

3. Superior Weld Quality.

K-TIG virtually eliminates the potential for inclusions, porosity, and other defects.

K-TIG is fully capable of welding autogenously, or with the addition of filler material during the keyhole pass, without multiple fusion lines. This virtually eliminates the potential for lack of fushion and inclusions and dramatically reduces the potential for porosity and other defects typical of many welding processes. It is a low distortion process, with heat inputson the low end of normal ranges. As a result, transverse shrinkage and angular (peaking) distortion are greatly reduced.

K-TIG’s weld pool provides an exceptional quality crown and root that requires no back-gouging, finishing, cleaning or interpass grinding.

 

4. Productivity Improved.

With its extraordinary speed, K-TIG delivers significant productivity gains and labour cost savings.

In addition to very tangible savings in labour time (with weld times up to 100x faster than TIG/GTAW), K-TIG offers significant intangible savings. Most importantly, K-TIG customers usually see a 50%+ boost in productivity.

In addition, the stress on the operator is vastly reduced, welding fatigue is greatly reduced and operator focus can be fully directed to process supervision and quality control rather than the physically and mentally taxing process of performing the weld manually.Download the GE Case Study and see how they saved 93% with K-TIG 

From a complexity standpoint, we’ve found it’s not much different from any of our automated welding equipment.  There is a training period, and a reasonably competent welder is able to understand and come up to speed quickly, and at that point, the machine is pretty intuitive. There are few settings you need to adjust, a competent welder is able to understand that and come up to speed quickly.
Jeff Thomas, Vice President, Operations, TITAN Metal Fabrication

 

5. Bye Bye Bevelling.

With no edge bevelling or root gaps, K-TIG reduces preparation and weld time, as well as labour costs.

K-TIG welds require no edge bevelling. Save the time, labour, energy and cost of V-prepping your materials. Eliminate the need for setting root gaps. Tack welds are simply consumed in the K-TIG process. K-TIG can also be used to perform a sealing pass around the joint prior to welding if airtight purging is required for reactive materials such as titanium.

 

6. Low Distortion. High Stability.

A low distortion process, K-TIG greatly increasing the likelihood of structurally sound welds.

K-TIG welding is a low distortion process. Unlike plasma, laser and electron beam welding, K-TIG is more tolerant of joint fit-up imperfections such as joint gap or mismatch and creates a highly stable, self-correcting full-penetration keyhole across a wide spectrum of metals.

Download the Bilfinger Case Study and see how they saved 92% welding 321 Pressure Vessels

 

7. Simple Automation, Sophisticated Welding.

Simple or sophisticated automation, you choose. K-TIG’s only requirement - consistent travel speed.

A whole range of welding automation equipment (including most existing welding automation equipment) can be used in conjunction with K-TIG, including:

  • Rotators
  • Positioners
  • Turntables
  • Seamers
  • Column and boom
  • Bugs and motorised carriages
  • Robots
  • Manipulators
When compared to TIG/GTAW for the same weld, K-TIG reduces power consumption by up to 95% and consumption by up to 85%, dramatically reducing the carbon footprint of our customers.
Jeff Thomas, Vice President, Operations, TITAN Metal Fabrication.

9. Variety of Applications.

K-TIG delivers exceptional quality across a wide range of materials.

K-TIG provides exceptional quality welds across a wide range of corrosion resistant, exotic and conventional materials, and excels in the medium to heavy gauge austenitic metals, including:

  • Titanium and Titanium Alloys
  • Zirconium and Zirconium Alloys
  • Stainless Steels - Austenitic, Duplex and Super-Duplex
  • Nickelalloys - Monel, Inconel, Incoloy, Hastelloy, Nimonic
  • Nickel Alloys

 

10. Simplicity Itself.

K-TIG’s fully automated process is extremely easy to use and maintain.

Our system features an arc structure and keyhole that develop spontaneously and are maintained automatically. There is no plasma nozzle or orifice, and no precise electrode alignment is required. Plus, only one welding gas is required, flow rate is not critical, and the torches are built tough.

 

11. Consumables Slashed.

The K-TIG system makes wire an option not a requirement, and reduces gas and power enormously.

K-TIG welds with square butt presentations, typically reduce the use of wire consumables by 90%, or eliminate the use of filler materials altogether.

Electrodes aren’t consumed in the weld pool, making electrode life extremely long—five K-TIG electrodes last most fabricators 12 months.

Finally, power consumption is reduced by up to 95%, and gas consumption is reduced by up to 85%.

The savings—in cost, time, labour and impact on the environment—are enormous.

Download the TITAN Case Study and see how they reduced thier wire consumption by 75%.

 

12. Environmentally Friendly.

K-TIG consumes considerably less power, gas and consumables than traditional welding methods.

Industrial fabrication, and conventional welding process in particular, is a highly energy intensive process, involving the consumption of large quantities of gas, electricity and consumables.

 

Check out our Equipment page.

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