K-TIG performs single-pass, full-penetration welds of up to 5/8 inch (16mm), providing order-of-magnitude increases in productivity, with welding speeds up to 100x faster than conventional TIG/GTAW welding.
For example, a multi-hour conventional TIG weld is reduced to just 3 minutes when using K-TIG.
K-TIG achieves all this without edge preparation, and joints can be presented in closed square-butt configuration. This represents enormous productivity and costs savings for a wide range of applications.
In fact, K-TIG typically reduces welding time by as much as 90%.
What is a K-TIG Weld Savings Assessment?
K-TIG regularly provides in-depth Weld Savings Assessments for both existing and potential customers.
Using the information and data that you provide, our Assessments compare your existing welding process to K-TIG, based on welding the exact same material, thickness, joints and lengths.
At the end of our Assessment, you receive a detailed, customised report that clearly demonstrates how your existing welding process compares to K-TIG. The report includes a range of parameters, from preparation, welding, cleaning and grinding times, through to welding speeds and consumable consumption rates.
With all these details on-hand, you can quickly and easily calculate what your expected return on investment (ROI) is likely to be (keeping in mind that payback is likely to be measured in months, rather than years). Combined with the clear visual representations of savings and productivity gains included in our report, these ROI figures make K-TIG’s superior performance metrics tangible and arm you with a clear business case for the purchase of our advanced welding technology.
Our Weld Savings Assessments have proved, time and again, to be an invaluable resource for our customers. As such, we wanted to provide you with an easy-to-understand breakdown of what you receive when you undertake a K-TIG Weld Savings Assessment, as well as when and why to request one.
Using the real-world project examples outlined below, you can see that our Weld Savings Assessments demonstrate exactly how much welding time can be reduced, and how much productivity can be increased, with the implementation of K-TIG.
Real World Example One: Stainless Steel Fabricator
K-TIG provided a number of Weld Savings Assessments for a stainless manufacturer in the US specialising in general-purpose tanks, high-pressure cylinders and transport vessels.
The company requested assessments for both 6,350mm (250 inch) circumferential and 1,800mm (72 inch) longitudinal joints. The productivity gains across all assessments proved to be dramatic.
K-TIG delivered huge productivity savings for 6,350mm (250 inch) length joints in Stainless Steel 304 – 316 in a variety of thicknesses:
- At 10Ga (3.5mm): K-TIG took just 6 minutes, compared to 61 minutes for TIG/MIG
- At 7Ga (4.7mm): K-TIG took just 10 minutes, compared to 80 minutes for TIG/MIG
- At 6mm (1/4 inch): K-TIG took just 12 minutes, compared to 99 minutes for TIG/MIG
- At 8mm (5/16 inch): K-TIG took just 16 minutes, compared to 99 minutes for TIG/MIG
- At 9.5mm (3/8 inch): K-TIG took just 21 minutes, compared to 112 minutes for TIG/MIG
K-TIG also delivered exceptional productivity savings for 1,800mm (72 inch) length joints in Stainless Steel 304 – 316 in a variety of thicknesses:
- At 10Ga (3.5mm): K-TIG took just 1.8 minutes, compared to 18 minutes for TIG/MIG
- At 7Ga (4.7mm): K-TIG took just 2.8 minutes, compared to 23 minutes for TIG/MIG
- At 6mm (1/4 inch): K-TIG took just 4.5 minutes, compared to 12 minutes for TIG/MIG
- At 8mm (5/16 inch): K-TIG took just 4.5 minutes, compared to 29 minutes for TIG/MIG
- At 9.5mm (3/8 inch): K-TIG took just 6 minutes, compared to 34 minutes for TIG/MIG
Real World Example Two: Titanium Products Fabricator
Similarly, K-TIG recently provided a Weld Savings Assessment for a world leading US based fabricator of titanium products
This company was in the process of quoting for a job that required the welding of a 9.5mm (3/8 inch) thick joint, using Alloy 20— a nickel-chromium-molybdenum alloy developed for applications involving sulfuric acid. There were two different joints to be welded, which were quite large, at 3.8m (150 inches) in length.
When the company contacted K-TIG to provide an assessment, their estimators and workshop leading hands had already provided estimates on the time required to complete the work.
Their estimators had determined that using TIG or GTAW for root passes, followed by flux-cored GMAW for fill and cover passes, the job would require at least 12 passes per joint. As such, the time required to complete the job was expected to be:
- 12 hours for set up time
- 67 hours for arc-on time
- 13 hours for interpass, cleaning and grinding
K-TIG could complete the same weld in just 48 minutes.
That is an arc-on time saving of 98.8%.
This remarkable saving is made possible because of K-TIG’s ability to perform a full-penetration weld in a single pass, combined with the eradication of cleaning and grinding.
Real World Example Three: US Thermal Technology company
K-TIG also provided a Weld Savings Assessments for a US thermal technology company. In this Assessment, we compared K-TIG to their existing TIG and MIG welding process. The company was using TIG and MIG to weld a 203mm (8 inch) pipe joint in 304 / 316 stainless steel. The job called for a square butt joint that was 8mm (5/16 inches) thick and 660mm (26 inches) in length.
The existing welding process required an arc-on time of 19 minutes. With K- TIG, the same weld took just 2 minutes, equating to a savings of 90.9%.
Similarly, the existing welding process required an additional 19 minutes of grinding and preparation time. With K-TIG, there was no grinding or preparation time required at all.
K-TIG also reduced wire consumption from 1kg to 0.01kg, and gas consumption was reduced from 285 litres to just 52 litres.
How to Request A K-TIG Weld Savings Assessment
Our Weld Savings Assessments are designed to gather key data so that we can help you make an informed decision about your welding processes and technology.
If you opt for a free, no obligation Weld Savings Assessment, you’ll just need to provide some basic information about your existing welding processes, including:
- What welding process or processes do you use now?
- What is your typical welding speed? How many mm per minute?
- What sort of material and joints (including length and thickness) are you welding?
- What sort of weld preparation do you undertake? How long does this take?
- What is your filler material feed rate? How much filler do you use (in either mm per minute or total weight)?
- What is the gas flow-rate for your welding torch and purging or backing gas?
- Do you undertake any interpass grinding or cleaning? How long does this takes?
Based on your answers to these questions, we can compile an in-depth analysis of exactly how your existing welding process compares to K-TIG across several criteria, from arc-on time, grinding and overall labour savings, through to wire and gas consumption reductions. As such, you’ll understand the productivity gains (parts welded per day or week) you can expect if you decide to switch to K-TIG.