Abstract: A welding torch assembly includes a mounting plate. A welding torch is mounted to the mounting plate. The welding torch includes an adjustment track fixed to the mounting plate, an adjustment body slidable relative to the adjustment track, a torch body, an electrode holder having a longitudinal axis. An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. A working end portion includes a second truncated cone. The elongated body is located between the seating portion and the working portion. A retaining nut secures the electrode in the electrode holder. The electrode retaining nut contacts the angled surface of the seating end portion. A shield gas cup is secured to the torch body that forms a welding arc to melt filler wire.

Abstract: A plasma arc welding system includes at least two wire delivery mechanisms and at least two wires. Each of the two wires is delivered by one of the at least two wire delivery mechanisms.

Abstract: An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. The first truncated cone has a first truncated end and an opposing conical end. A working end portion includes a second truncated cone having a second truncated end. A constant length is defined between the opposing conical end and the second truncated end. The constant length is about 0.875 inch +/?0.001 inch. The elongated body is located between the seating end portion and the working end portion.

Abstract: A welding torch assembly includes a mounting plate. A welding torch is mounted to the mounting plate. The welding torch includes an adjustment track fixed to the mounting plate, an adjustment body slidable relative to the adjustment track, a torch body, an electrode holder having a longitudinal axis. An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. A working end portion includes a second truncated cone. The elongated body is located between the seating portion and the working portion. A retaining nut secures the electrode in the electrode holder. The electrode retaining nut contacts the angled surface of the seating end portion. A shield gas cup is secured to the torch body that forms a welding arc to melt filler wire.

Abstract: An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. The first truncated cone has a first truncated end and an opposing conical end. A working end portion includes a second truncated cone having a second truncated end. A constant length is defined between the opposing conical end and the second truncated end. The constant length is about 0.875 inch +/?0.001 inch. The elongated body is located between the seating end portion and the working end portion.

Abstract: An electrode includes a working end portion defining a first truncated cone. A seating end portion defines a second truncated cone and including a threaded portion having a plurality of threads with a thread angle of 55°. An elongated body defines a longitudinal axis. The elongated body is located between the seating end portion and the working end portion. A method is also disclosed.

Abstract: A nozzle for a welding torch includes a body portion defining an internal bore, a discharge orifice, and an internal radius on the internal bore proximate to the discharge opening.

Abstract: An electrode includes an elongated body defining a longitudinal axis. A seating end portion includes a first truncated cone. The first truncated cone has a first truncated end and an opposing conical end. A working end portion includes a second truncated cone having a second truncated end. A constant length is defined between the opposing conical end and the second truncated end. The constant length is about 0.875 inch+/?0.001 inch. The elongated body is located between the seating end portion and the working end portion.

Abstract: A welding system includes a gas tungsten arc welding power source having a welding arc contactor, a plasma welding torch, and a gas console that supplies gases to the plasma welding torch. The welding system also includes a coolant flow switch connected in series with the welding arc contactor. Power is not provided from the gas tungsten arc welding power source to the plasma welding torch when the coolant flow switch is not actuated.

Abstract: A welding apparatus spot welds an upper sheet and a lower sheet together. A substantially semi-circular hole or notch is formed at an edge of the upper sheet at the desired location of spot welding. When the semi-circular hole or notch is formed, the process does not wrinkle or deform the upper sheet. A clamping cup of the welding apparatus surrounds the semi-circular hole or notch and contacts the upper surface of the upper sheet. A plasma arc torch heats the sheets, allowing entrapped vapors in a coating on the lower sheet to vent freely to the atmosphere. Filler wire is added and melted to fill the semi-circular hole or notch and to secure the overlapping sheets together.

Abstract: A method of aligning and duplicating alignment includes welding a washer over a larger opening in a hinge once in an aligned position relative to a vehicle door. The door is mounted into an alignment fixture and the hinges are installed over threaded studs extending from the door. The washer is placed onto the threaded stud and tightened against the hinge, covering the larger opening in the hinge. The larger opening in the hinge allows movement of the hinge relative to the door for alignment. The washer defines an opening with a smaller opening sized to provide relatively little clearance for the threaded stud, and thereby maintain alignment between the door and hinge. The washer is permanently attached by a welding operation to allow duplication of door hinge alignment during reassembly.

Abstract: A welding apparatus welds two or more overlapping members having a tenacious surface oxide layer. The apparatus includes a plasma arc torch operable to form a weld pool in a work piece and a weld pool disturbing device operable, in use, to disturb a weld pool formed by the plasma arc torch. The weld pool disturbing device includes a disturbing member which is movable into the weld pool. The apparatus may include a support member adapted to support the weld pool.

Abstract: A welding apparatus spot welds two or more overlapping sheets having a coating, such as zinc coated steel or aluminum alloy with an oxide coating. A hole is formed in the upper sheet at the desired point of spot welding. A clamping cup of a plasma arc passes surrounds the hole and contacts the upper surface of the upper sheet. The torch heats the sheet, allowing entrapped vapors in the coating on the lower sheet to vent freely. Filler wire is added to fill the hole and to secure the overlapping sheets together. If the overlapping sheets are zinc coated steel, preferably the filler wire is copper based.

Abstract: A welding apparatus spot welds two or more overlapping sheets having a coating, such as zinc coated steel or aluminum alloy with an oxide coating. A hole is formed in the upper sheet at the desired point of spot welding. A clamping cup of a plasma arc passes surrounds the hole and contacts the upper surface of the upper sheet. The torch heats the sheet, allowing entrapped vapors in the coating on the lower sheet to vent freely. Filler wire is added to fill the hole and to secure the overlapping sheets together. If the overlapping sheets are zinc coated steel, preferably the filler wire is copper based.

Abstract: A method and assembly for spot welding metal sheets includes a conductive metal strip sandwiched between an electrode and the sheet metal to be welded. The conductive strip shields the electrodes from deterioration accelerating coatings present on the sheet metal to be welded. The conductive strip deteriorates instead of the electrode and is indexed through the welding interface after a desired number of welds.

Abstract: A method of curing a thermosetting adhesive (18) provided at the interface of two overlapping members (12, 14), the method comprising the steps of: providing two overlapping members (12, 14) having at their interface a thermosetting adhesive (18); providing plasma discharge heating means (24) operable to produce a plasma jet (42); and operating said plasma discharge heating means (24) to produce a plasma jet (42) to heat the or each overlapping member (12, 14) and thereby cure said thermosetting adhesive (18).

Abstract: A method of aligning and duplicating alignment includes welding a washer over a larger opening in a hinge once in an aligned position relative to a vehicle door. The door is mounted into an alignment fixture and the hinges are installed over threaded studs extending from the door. The washer is placed onto the threaded stud and tightened against the hinge, covering the larger opening in the hinge. The larger opening in the hinge allows movement of the hinge relative to the door for alignment. The washer defines an opening with a smaller opening sized to provide relatively little clearance for the threaded stud, and thereby maintain alignment between the door and hinge. The washer is permanently attached by a welding operation to allow duplication of door hinge alignment during reassembly.

Abstract: The invention provides a plasma welding or brazing process in which a direct current pilot arc is maintained throughout the process. The process comprises the steps of setting a pilot arc power supply (6) to a relatively high level, generating a high voltage spark discharge between a non-consumable electrode (14) of a plasma welding or brazing torch (2) and a nozzle (18) of said torch in order to start the flow of a pilot arc current, detecting the pilot arc current and reducing the pilot arc current to a relatively low level. The invention further provides apparatus for carrying out plasma arc welding, comprising a plasma welding torch, a controller and a power supply. The controller further comprises means for detecting the flow of a pilot arc current and or a main arc current and means for reducing this current on detection.

Abstract: A welding apparatus spot welds two or more overlapping sheets having a coating, such as zinc coated steel or aluminum alloy with an oxide coating. A hole is formed in the upper sheet at the desired point of spot welding. A clamping cup of a plasma arc passes surrounds the hole and contacts the upper surface of the upper sheet. The torch heats the sheet, allowing entrapped vapors in the coating on the lower sheet to vent freely. Filler wire is added to fill the hole and to secure the overlapping sheets together. If the overlapping sheets are zinc coated steel, preferably the filler wire is copper based.