What TIG and Its Finish Work Actually Cost
TIG is the incumbent joining process for sanitary stainless because it is clean, and it is also one of the slowest common processes. An alloy producer's own welding guide puts suggested manual GTAW travel at 4 to 6 inches per minute and states plainly that deposition rates during manual welding are low; trade references put TIG-class deposition around 1 to 3 lb/hr. The Sheet Metal and Air Conditioning Contractors' association's 2024 comparison states laser welding exceeds TIG speed 'by 4X or more,' and IPG (the handheld category benchmark, whose claims are attributed here as its own marketing) publishes '4x Faster than TIG' and that novice operators require less training.
Sanitary welds then carry a second, quieter invoice: the finish work. 3-A-type requirements mean full-penetration welds free of porosity, undercut and crevices, blended back to the base-metal finish: grinding and polishing labour after every weld, on exactly the thin sheet where heat and pressure turn into distortion. No published per-weld polishing time exists; the one quantified finishing-step number in the literature is chemical: pickling a 6-inch weld takes 20 to 30 minutes, versus 30 to 60 seconds for electrochemical cleaning of the same weld.
The chemical route also carries handling most shops would rather retire: traditional pickling paste is hydrofluoric plus nitric acid, WHMIS-controlled from cupboard to disposal, and after pickling a separate passivation step is still required. ASTM A967 governs chemical passivation; citric-acid routes are published as costing 60 to 80% less in disposal than nitric. Two scoping facts keep this honest: passivation does not replace weld-scale removal, and heat tint and embedded iron must be dealt with first; that removal slot is what electrochemical systems and laser cleaning compete for.
Downstream of the fabricator, the customer's clock justifies the spend: published compilations put food and beverage downtime at $4,000 to $30,000 per hour as a general range, with industry calculators claiming far more for full production lines; a Siemens study reports average incident resolution time grew from 49 to 81 minutes even as incident counts fell. A fabricator's lead time on a replacement hopper, auger or conveyor pan is priced by the plant in those dollars, which is what same-week, in-house cutting and welding capability is actually for.