Core Working Principle
Essentially, this process adds an independent filler wire preheating system to conventional Tungsten Inert Gas (TIG) welding. There are two mainstream implementation methods:
Resistance Heating Method: A dedicated power source is connected between the filler wire and the workpiece; preheating is achieved via the heat generated by the wire's own electrical resistance. This method features a simple structure and low cost, making it the standard solution for conventional commercial models.
High-Frequency Induction Heating Method: Non-contact preheating of the filler wire is achieved through electromagnetic induction. This avoids magnetic field interference and offers extremely high temperature control precision, making it suitable for high-end, precision welding applications such as nuclear power and aerospace.
Mainstream Technical Variants
TIGer Dual-Tungsten Hot-Wire TIG Welding
A derivative technology developed by Polysoude. A single torch houses two tungsten electrodes paired with two independent power sources (master and slave) to generate a composite arc. While maintaining the same total energy input, it reduces base metal penetration depth and utilizes the excess energy to preheat the filler wire. Deposition rates reach 2.5–6 kg/h, and welding speeds increase to 500–1000 mm/min; efficiency is three times that of standard hot-wire TIG, with welding costs reduced by 20%–50%.
Advanced Hot-Wire TIG Circuit Technology
This technology optimizes circuit control strategies, enabling rapid welding even at low current levels and significantly enhancing operational stability. It is compatible with various metals-including stainless steel, aluminum alloys, and titanium alloys-and reduces the occurrence of welding defects.
High-Efficiency Hot-Wire TIG Process
An upgraded process developed independently in China that overcomes the efficiency bottlenecks of traditional hot-wire TIG. Wire feed speeds reach up to 6.5 m/min, and deposition rates increase to 2–4 kg/h. Compared to standard cold-wire TIG, overall efficiency is improved by 5 to 10 times. Welds consistently meet Class I inspection standards, and joint performance surpasses that of traditional processes, effectively breaking the monopoly held by overseas technologies.
