Abstract: A welder for welding a base metal. The welder may include a first electrode for forming a first arc with the base metal and a second electrode for forming a second arc between the first and second electrodes. A compact welder, welding system, and method are also provided.

Abstract: A system, in some embodiments, includes a multi-torch power supply. The power supply has a first circuit configured to control output to a first electrical torch, and a second circuit configured to control output to a second electrical torch. The power supply also has a power source configured to supply power to the first and second circuits to enable both independent and simultaneous operation of the first and second electrical torches.

Abstract: Remote-controlled joining system for subsea pipelines for joining two smooth pipeline ends (pipe ends) that are arranged facing in line a distance apart, with means arranged to move at least one of the pipeline ends sideways and in the longitudinal direction. The joining system is distinguished by comprising: a pipe sleeve having internal seals against each pipeline surface, for insertion of pipe ends to facing position within the seals, and a welding clamp with integrated welding tool for remotely welding of a first end of the pipe sleeve to the first pipeline and a second end of the pipe sleeve to the second pipeline, the welding clamp can be remotely fastened sealingly around the pipe ends and the sleeve and is equipped with means for establishing and maintaining a welding atmosphere in a volume delimited by the seals of the clamp and the seals of the sleeve.

Abstract: A welding apparatus is provided for carrying a welding gun across or past a surface for making welds. The apparatus may include one or more rolling components, such as wheels for example, that do not substantially plastically deform as a result of contacting or being in close proximity to recently completed welds or preheated joints and provide adequate traction to move the apparatus across or past the surface. A portion of the contact surface of the rolling component may be configured with a given surface roughness to provide sufficient traction.

Abstract: Bucket tip tenons requiring refurbishment are removed from the bucket tips by grinding. Groups of buckets are clamped on a rotatable table in positions adjacent an induction heating coil and a robotic welding arm, respectively. While one group is preheated, the other group of buckets is in a welding location, enabling the welding head on the robotic arm to sequentially apply weld buildup material to the bucket tips. After applying weld buildup material in multiple passes and sequentially to the bucket tips, the buckets are removed, stress-relieved and the weld buildup material machined to provide refurbished tenons. Upon removal of the buckets from the table, the table is rotated to locate the preheated buckets in welding locations and additional buckets are clamped to the table for preheating.

Abstract: A plasma arc torch and methods for assembling and disassembling a plasma arc torch wherein a plurality of front end parts of the torch form a unit that is removable from the torch in a single operation to gain access to the electrode. The unit can then be reinstalled in the torch in a single operation after replacement of the electrode. An assembly fixture is employed to facilitate pre-assembly of the unit of front end parts prior to installation of the unit in a torch.

Abstract: An improved fusion welding system having a perforating device and a heating combination is adapted for welding in tandem a set of adjacent overlapping workpieces. The system preferably includes a first laser that perforates the workpieces to produce an opening spaced from the edges; and the combination preferably includes a second laser and electrode for cooperatively melting fusible material into the opening.

Abstract: In an electrode for generating a plasma, disposed to face a surface of a substrate to perform a plasma processing on the surface of the substrate, the electrode includes a metal-based composite material formed by impregnating a metal into a base member made of a porous ceramic, and having a joint surface at least facing toward the entire surface of the substrate. The electrode also includes a conductive plate made of a plasma-resistant material melt-bonded by a metal to the joint surface of the metal-based composite material.

Abstract: A plasma welding method for a golf club head includes the steps of: preparing a club head body and a striking plate, and mounting the striking plate to the club head body; moving a plasma nozzle to aim to a connection line formed between the club head body and the striking plate before the plasma welding; tilting the plasma nozzle a predetermined inclined angle with respect to a vertical direction of the combination of the club head body and the striking plate for the plasma welding; and controlling the tilted plasma nozzle to weld the striking plate to the club head body so as to constitute the golf club head.

Abstract: A device for clamping at least two components for use in friction stir welding supports the components and holds the components in place using a plurality of channels placed under vacuum for clamping of the components during friction stir welding. Both sides of a welding backup plate may have a mounting device including the vacuum channels, for example. The mounting device may have a contoured support surface for supporting components with a simple or complex surface curvature, allowing the same device to be rapidly configured to a plurality of component types with varying surface curvatures.

Abstract: The invention relates to a protective cap for at least one contact pipe of a welding torch, the pipe or pipes having a respective bore for guiding and contacting a respective welding rod that is fed through the pipe or pipes. The cap comprises a housing consisting of or coated with a poor electrically conductive material, for receiving the contact pipe and a bore, which allows the welding rod to emerge. The aim of the invention is to increase the service life of a contact pipe or a welding torch comprising at least one contact pipe of this type. To achieve this, at least two openings are provided in the housing for receiving at least two contact pipes and each opening is connected to one respective bore in the housing for receiving at least two contact pipes and each opening is connected to one respective bore in the housing. Each bore is positioned in such a way that it corresponds with the course of the welding rod in the contact pipe, once the protective cap has been mounted.

Abstract: A method and apparatus for automatically determining a consumable type when a consumable is disposed within an electrode holder of a welding-type system is disclosed. The invention includes a detector assembly that measures a physical characteristic of a connected consumable and provides feedback regarding that which is measured. From the feedback, the operating parameters of a welding-type process may be automatically prescribed.

Abstract: Disclosed herein is an automatic pulse plasma welding method and apparatus for forming a lap joint between membrane sheets, which applies plasma welding to a lap joint between membrane sheets to improve working efficiency and productivity, and which provides optimal welding conditions to the respective regions of the lap joint between membrane sheets to improve welding quality.

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 guide that is used in conjunction with a plasma cutting torch includes a main circular ring having a small circular ring mounted on the outer periphery thereof. The small ring includes a bearing assembly and accommodates the plasma cutting torch. A guide bolt is mounted on the main circular ring and is attached to the workpiece and forms the center of a circular hole that will be cut with the plasma torch. Once the main ring is attached to the workpiece, the plasma torch is attached to the small ring. The torch and rings are then rotated about the bolt with the plasma torch activated to cut a hole that has a radius equal to the radius of the main circular ring plus the radius of the small ring.

Abstract: A torch lead extension is provided that comprises a conduit having a distal end and a proximal end. The torch lead extension further comprises a distal connector member disposed at the distal end of the conduit and a proximal connector member disposed at the proximal end of the conduit. The distal connector member is engageable with a torch lead connector member secured to a proximal end of a torch lead. The proximal connector member is engageable with a power supply connector member of a power supply. Generally, the distal connector member and the torch lead connector member comprise a distal quick disconnect, and the proximal connector member and the power supply connector member comprise a proximal quick disconnect. Accordingly, the torch lead extension may be quickly assembled between or disassembled from the torch lead and the power supply.

Abstract: Electrode and nozzle that seat within a retaining member and in two different seating locations relative to retaining member. The electrode and nozzle each include an interwoven-double-start thread having two thread cuts, which start 180 degrees from one another as measured around the circumference of the electrode or nozzle. Further, the electrode, nozzle, and retaining member include mating frustum surfaces, which are configured and dimensioned so that the electrode and nozzle seat within the retaining member with less than one turn of the electrode and nozzle relative to the retaining member. Therefore, the electrode and nozzle may be quickly inserted in, and removed from, the retaining member.

Abstract: The invention relates to a method and an apparatus for plasma welding. A free microwave-induced plasma jet is generated by the following steps. Microwaves are generated in a high-frequency microwave source. The microwaves are guided in a wave guide. A process gas is introduced at a pressure of p?1 bar into a microwave-transparent tube, which comprises a gas inlet opening and a gas outlet opening, the process gas being introduced through the gas inlet opening into the microwave-transparent tube in such a way that it has a tangential flow component. A plasma is generated in the microwave-transparent tube by electrodeless ignition of the process gas. The plasma jet is produced by the introduction of the plasma into a working space through a metallic expansion nozzle arranged at the gas outlet opening of the tube.

Abstract: According to one embodiment of the invention, a method for controlling operational weld parameters of a welding-based deposition process includes generating a solid model representing a three-dimensional part on a computer, electronically slicing the solid model into a plurality of electronic two-dimensional layers, identifying a path of material deposition based on the electronic two-dimensional layers, the path comprising a plurality of deposition points, and determining a geometrical factor for each deposition point. The geometrical factor is defined by a ratio of an actual volume of material around each deposition point to a theoretical volume of material around each deposition point. The method further includes automatically adjusting, during material deposition for a respective deposition point, one or more parameters of the welding-based deposition process based on the geometrical factor for the respective deposition point.

Abstract: A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by plasma transferred arc welding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.

Abstract: A device for allowing a rotating plasma arc to perform cutting or welding operations inside tubes with small inside diameters by being attached to existing plasma arc power sources where in the speed and axis of rotation of the arc are controlled by the device, and the components of the device in proximity to the plasma arc itself are protected by the ceramic composition of the device and an inert gas shield.

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 self-contained crucible assembly for forming a weld between a pair of metal articles, includes a container with side walls and a fusible bottom, a refractory material lining the side walls, an exothermic weld material within the container, an ignitor partially within or close to the weld material and partially external to the container, and a cover sealing the weld material. The ignitor may be stiffened to maintain its shape, and keep it in a desired position relative to the exothermic weld material. The crucible assembly is configured to be placed on mold having a chamber therein. Upon ignition of the weld material via actuation of the ignitor, the weld material reacts exothermically to produce molten weld metal and slag. The fusible bottom of the container is melted by the liquified molten metal, and the weld material flows into a weld chamber of the mold to produce the weld.

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 apparatus for bonding a circuit component to a circuit package or board is presented. A pressurized directional flow of plasma is applied between attachment sites of the component to be bonded and the corresponding bond pad of the package/board. During the application of plasma between the bonding surfaces, direct contact fusion/diffusion bonds the component attachment sites to the corresponding bond pads.

Abstract: Methods and apparatus for initiating a welding arc by directing a plasma jet into the space between the tip of the welding electrode and the workpiece. This is done while an electrical potential is applied between the electrode and the workpiece. The ionized plasma gas renders the space between the electrode and the workpiece more conductive, thereby reducing the voltage threshold needed to initiate an arc between the electrode and the workpiece. When the voltage threshold reaches the level of the applied electrical potential, the arc will be initiated.

Abstract: A stationary shroud of a gas turbine engine made of a base metal is repaired by removing any damaged material from a flow-path region of the stationary shroud to leave an initially exposed base-metal flow-path surface; and applying a base-metal restoration overlying the initially exposed flow-path surface. The base-metal restoration is applied by furnishing a source of a structural material that is compatible with the base metal, and depositing the source of the structural material overlying the initially exposed base-metal flow-path surface of the stationary shroud by plasma transferred arc welding to form a repaired base-metal flow-path surface. An environmentally resistant rub coating may be applied overlying the base-metal restoration.

Abstract: An apparatus, system and related method are disclosed for performing trackless movement and full penetration welding along a weld line, irrespective length and configuration of a butt joint. A pre-existing gap of the weld line is used to act a guide slot and a guide wheel unit to track the gap is designed to perform trackless movement using an electric or manual winch as a driver. In the automatic arc welding systems, the guide slot and the guide wheel unit can save an external track and a seam-tracking device. A movable weld backing is held against the underside of the weld line to support liquid metal and control backside bead to achieve full-penetration welding of a butt weld. The movable weld backing and a welder are arranged the underside and the topside of base metals to be welded, respectively, using a connector member through the pre-existing gap of the weld line. According to the apparatus, flux-cored wire plasma arc can perform full penetration welding.

Abstract: An apparatus, system and related method are disclosed for performing trackless movement and full penetration welding along a weld line, irrespective length and configuration of a butt joint. A pre-existing gap of the weld line is used to act a guide slot and a guide wheel unit to track the gap is designed to perform trackless movement using an electric or manual winch as a driver. In the automatic arc welding systems, the guide slot and the guide wheel unit can save an external track and a seam-tracking device. A movable weld backing is held against the underside of the weld line to support liquid metal and control backside bead to achieve full-penetration welding of a butt weld. The movable weld backing and a welder are arranged the underside and the topside of base metals to be welded, respectively, using a connector member through the pre-existing gap of the weld line. According to the apparatus, flux-cored wire plasma arc can perform full penetration welding.

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: Exothermic reaction mixtures are electrically ignited with a low cost foil strip of two conductive strips separated by a layer of insulation. One or more holes are formed in the ignitor to create shaped spark plasma on one side and a venting plasma on the opposite side of the hole. The spark with low energy requirements is sufficient to ignite exothermic reactions for welding, casting and other uses. The ignitor may be part of reusable crucibles and molds, or expendable packages, containers, and molds, or smaller squibs for igniting larger charges. The ignitor may be immersed in or substantially adjacent the charge of exothermic material. The spark forming hole or holes is made and shaped by a punch in a simple and low cost manner. The ignitor eliminates the need for starting powders or materials and flint gun ignitors.

Abstract: A method and apparatus for sealing a package over/around a circuit is presented. A pressurized directional flow of plasma is applied between metal bonding edges of the package and a metal surface surrounding circuitry to be enclosed in the package. During the application of plasma between the bonding surfaces, a bonding devices direct contact fusion/diffusion bonds the metal bonding edges of the package to the metal bonding surface surrounding the circuitry to be enclosed.

Abstract: Methods and apparatuses for plasma MIG welding or TIG MIG welding are disclosed. They include a plasma or TIG torch for following along a weld path by a MIG torch (or the order may be reversed). A constant distance may be maintained between the torches, and the angle of the torches, relative to the workpiece, may vary. The MIG process is performed EP or EN in various embodiments.

Abstract: A method and apparatus for providing welding type power is disclosed. The power source is capable of receiving any input voltage over a wide range of input voltages and includes an input rectifier that rectifies the ac input into a dc signal. A dc voltage stage converts the dc signal to a desired dc voltage and an inverter inverts the dc signal into a second ac signal. An output transformer receives the second ac signal and provides a third ac signal that has a current magnitude suitable for welding, cutting or induction heating. The welding type current may be rectified and smoothed by an output inductor and an output rectifier. A controller provides control signals to the inverter and a controller power supply can also receive a range of input voltages and provide a control power signal to the controller, and a voltage independent of the input voltage.

Abstract: A torch for powder plasma buildup welding capable of readily attaining welding in conformity to any size of a pipe material to be subjected to welding, any configuration thereof and the like. A torch head is replaceably connected to a torch body. The torch body is provided with a gap formation spacer member which is abutted against an inner peripheral surface of the pipe material to keep a distance between an opening of a convergent nozzle of the torch head and the inner peripheral surface of the pipe material substantially constant during buildup welding. Also, the torch body is provided with a deflection restraint spacer member which is abutted against the inner peripheral surface of the pipe material to prevent deflection of the torch body in the pipe material during buildup welding.

Abstract: Methods and apparatuses for plasma MIG welding or TIG MIG welding are disclosed. They include a plasma or TIG torch for following along a weld path by a MIG torch (or the order may be reversed). A constant distance may be maintained between the torches, and the angle of the torches, relative to the workpiece, may vary. The MIG process is performed EP or EN in various embodiments.

Abstract: A torch for powder plasma buildup welding capable of readily attaining welding in conformity to any size of a pipe material to be subjected to welding, any configuration thereof and the like. A torch head is replaceably connected to a torch body. The torch body is provided with a gap formation spacer member which is abutted against an inner peripheral surface of the pipe material to keep a distance between an opening of a convergent nozzle of the torch head and the inner peripheral surface of the pipe material substantially constant during buildup welding. Also, the torch body is provided with a deflection restraint spacer member which is abutted against the inner peripheral surface of the pipe material to prevent deflection of the torch body in the pipe material during buildup welding.

Abstract: A welding head for powder plasma arc welding (PPAW), comprising an electrode and a supporting jacket arranged coaxially around the electrode with inclusion of a first feed channel, in which supporting jacket an inner nozzle is received, such that the first feed channel extends in an axial flow direction along the electrode via a bore in the inner nozzle as far as a first outflow opening situated in an end face of the inner nozzle. The welding head further comprises an outer nozzle arranged coaxially around the supporting jacket, which outer nozzle surrounds the supporting jacket with inclusion of a second feed channel, such that the second feed channel, axially converging in the flow direction, extends as far as a second outflow opening. The welding head has a characteristic feature that the supporting jacket extends in the flow direction beyond the inner nozzle, such that the end face of the inner nozzle is situated upstream with respect to the end face of the supporting jacket.

Abstract: Two silicon workpieces (20, 22) welded together into one member without the formation of cracks along the weld. It may be formed by a first method in which current (34, 36) is passed through one or both of the workpieces to heat them to between 600 and 900° C. Then an electric, laser, or plasma welder (38, 40) passes along the seam (24) between the workpieces to weld them together. In a second forming method, current (34) is passed through a plate (60), preferably formed of silicon, which either supports the workpieces or is brought into contact with at least one of them, whereby the workpieces are preheated prior to the welding operation.

Abstract: A method and apparatus for bonding a circuit component to a circuit package or board is presented. A pressurized directional flow of plasma is applied between attachment sites of the component to be bonded and the corresponding bond pad of the package/board. During the application of plasma between the bonding surfaces, direct contact fusion/diffusion bonds the component attachment sites to the corresponding bond pads.

Abstract: A method and apparatus for bonding solid sheets together is presented. A modulated directional flow of plasma is applied at and between the bonding surfaces of the sheets to be bonded prior to and during the application of pressure to compress the bonding surfaces together to form a direct contact or diffusion bond.

Abstract: A method and apparatus for bonding solid materials together is presented. A modulated directional flow of plasma is applied at and between the bonding surfaces of members to be bonded prior to and during the application of pressure to compress the bonding surfaces together to form a direct contact or diffusion bond.

Abstract: A method and apparatus for bonding solid plates together is presented. A modulated directional flow of plasma is applied at and between the bonding surfaces of the plates to be bonded prior to and during the application of pressure to compress the bonding surfaces together to form a direct contact or diffusion bond.

Abstract: A shroud for a welding torch includes a hydrophilic skirt supported by a frame. The skirt is soft and pliable when wet and is self protected from the heat of welding by the water absorbed therein. The frame supports the skirt around the weld site and permits a good seal with the workpiece for excluding water during the welding process.

Abstract: An apparatus and method for producing an exhaust processor comprising: a clamping device for applying a predetermined clamping pressure to clamp a case or other component of the exhaust processor about a substrate or other component of the exhaust processor to define a gap between the case and substrate; a measuring device for measuring a size of the gap during application of the predetermined clamping pressure, the measuring device including a clamping pressure control system for adjusting the predetermined clamping pressure of the clamping device in response to the gap measurement so that the gap size is within a predetermined range; and a welder for welding a portion of the case component to an other portion of the caset when the gap size is within the predetermined range. The measuring device also includes a camera for measuring the gap size.

Abstract: A shroud for a welding torch includes a hydrophilic skirt supported by a frame. The skirt is soft and pliable when wet and is self protected from the heat of welding by the water absorbed therein. The frame supports the skirt around the weld site and permits a good seal with the workpiece for excluding water during the welding process.

Abstract: An object is to provide an optical fiber fusion splicing method in which splice loss can be reduced, and also to provide an arc-heating unit used for heating the fusion spliced part of an optical fiber. The method comprises a process of fusion-splicing together the end faces of two optical fibers and a process of continuously heating the fusion spliced part by arc while moving one pair of electrodes provided opposite to each other across the fusion spliced part. The arc heating process is performed with the operation for decreasing arc temperature.

Abstract: A torch for powder plasma buildup welding capable of readily attaining welding in conformity to any size of a pipe material to be subjected to welding, any configuration thereof and the like. A torch head is replaceably connected to a torch body. The torch body is provided with a gap formation spacer member which is abutted against an inner peripheral surface of the pipe material to keep a distance between an opening of a convergent nozzle of the torch head and the inner peripheral surface of the pipe material substantially constant during buildup welding. Also, the torch body is provided with a deflection restraint spacer member which is abutted against the inner peripheral surface of the pipe material to prevent deflection of the torch body in the pipe material during buildup welding.

Abstract: A method and apparatus for simultaneously cleaning and bonding a wire to a bonding surface is presented. In accordance with the invention, a gas is energized to form a plasma, which is then directed in a directional pressurized flow at the wire and bonding surface to form a dynamic plasma cleaning chamber bubble around the portion of the wire and bonding surface that are to be bonded together, and then the respective portions of the wire and bonding surface are bonded together within the plasma cleaning chamber bubble.

Abstract: An apparatus, system and related method are disclosed for sensing a characteristic of a workpiece, such as the location of a welding seam, using a sensor that is independent of another device for performing an operation on the workpiece, such as a welding torch for welding a seam. The sensor preferably takes the form of a plasma arc torch. This plasma arc torch travels along the workpiece, preferably just ahead of the welder for welding the workpiece or other implement and simultaneously moves to and fro in a direction transverse to the direction of travel of the welder. A non-transferred electrical arc serves to ionize a plasma gas issuing from the plasma arc torch to create a concentrated plasma jet directed towards the workpiece.