Abstract: The present disclosure is directed to ion-exchange systems and devices that can monitor key parameters related to the performance of the ion-exchange device. Specifically, the ion-exchange systems and devices disclosed herein can provide real time voltage drop across groups of membrane pairs using diagnostic spacer borders between the pairs. In addition, the ion-exchange systems and devices disclosed herein can monitor the compression force applied by the compression plates holding the ion-exchange systems and devices together.

Abstract: The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

Abstract: A method of controlling a weld penetration profile on a workpiece (306) having an outer region and an inner region is described. The method comprises the step of applying energy to the outer region of the workpiece with a welder (302) to produce a weld pool (304). The method also comprises the steps of penetrating the workpiece (306) such that the weld pool (304) spans between the outer region and inner region, and also applying a shielding gas to the inner region at a pressure that provides a force that limits weld penetration. A corresponding apparatus is also defined.

Abstract: The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire includes a sheath and a core, and the core includes an organic stabilizer component. Further, the organic stabilizer component includes an organic sub-component configured to release hydrogen near a surface of a workpiece during welding, and includes a Group I metal, Group II metal, or a combination thereof.

Abstract: The present disclosure relates generally to welding alloys and, more specifically, to welding consumables (e.g., welding wires and rods) for arc welding operations. In an embodiment, a welding consumable includes less than approximately 1 wt % manganese as well as one or more strengthening agents selected from the group: nickel, cobalt, copper, carbon, molybdenum, chromium, vanadium, silicon, and boron. The welding consumable also includes one or more grain control agents selected from the group: niobium, tantalum, titanium, zirconium, and boron, wherein the welding consumable includes less than approximately 0.6 wt % grain control agents. Additionally, the welding consumable has a carbon equivalence (CE) value that is less than approximately 0.23. The welding consumable is designed to provide a manganese fume generation rate that is less than approximately 0.01 grams per minute during a welding operation.

Abstract: A welding torch with a welding electrode and a welding electrode holder is provided. One welding torch includes a securing mechanism and an insulated grip. The securing mechanism is configured to secure an exposed central portion of a welding rod bounded by flux covered first and second sides. The securing mechanism is also configured to make electrical contact with the central portion of the rod for arc welding with the first side. The insulated grip is configured to cover the second side of the welding rod.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains lithium aluminate in either the flux or the electrode portion of the electrode.

Abstract: A filler wire (consumable) for depositing wear-resistant materials in a system for any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications. The consumable is composed of base filler materials consistent with commonly known compositions. For example, the base filler material can comprise standard materials used in many standard mild steel wires. In addition to the base filler materials, the consumable includes wear-resistant materials. The wear-resistant materials include at least one of diamond crystals, diamond powder, tungsten carbide, and aluminides.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains lithium aluminate in either the flux or the electrode portion of the electrode.

Abstract: A welding electrode comprising a metal core and a flux coating at least partially coated on an outer surface of said metal core, and also including a end coating material which at least partially inhibits porosity of a weld bead formed during the welding operation.

Abstract: A silver-containing antiseptic welding flux for stainless steel including 0.1-0.5 wt % of silver, 30-54 wt % of silicon dioxide, 20-40 wt % of titanium dioxide, 10-20 wt % of chromium oxide, 5-20 wt % of molybdenum oxide, 5-10 wt % of molybdenum sulfide, and 5-10 wt % of halide.

Abstract: The high efficiency welding device has two pairs of clamps mounted in two pairs of sliders movable in a reciprocating movement relative to one another. One pair of sliders is mounted at 0 and 180 degree positions around the circumferential surface of a support block and the other pair of sliders is mounted at 90 and 270 degree positions. Each pair of clamps is in the close condition while moving forward in the reciprocating movement to clamp onto selected air gaps of the welding electrode to advance the electrode towards the work piece as well as delivering the welding current to the welding operation, and it is in the open condition releasing the grasp of the welding electrode while moving backward.

Abstract: A Penetration Enhancing Activating Flux (PEAF) in paste form for autogenous TIG welding of austenitic stainless steels adapted for ready application with a brush on top weld surface prior to conducting autogenous TIG welding to favor single weld pass, of austenitic stainless steels of AISI 304LN and AISI 316LN varieties with weld bead penetration up to a section thickness of 12 mm. Importantly, the (PEAF) paste based TIG welding of the invention achieves an increase in weld bead penetration of about 300% over the conventional TIG process without activating flux. The PEAF paste based TIG welding also favors higher productivity and high quality apart from being cost-effective due to less requirement of consumables and controlled heat input to arrest distortion, making it widely acceptable for variety of industrial applications for welding of austenitic stainless steel.

Abstract: A welding torch with a welding electrode and a welding electrode holder is provided. One welding torch includes a securing mechanism and an insulated grip. The securing mechanism is configured to secure an exposed central portion of a welding rod bounded by flux covered first and second sides. The securing mechanism is also configured to make electrical contact with the central portion of the rod for arc welding with the first side. The insulated grip is configured to cover the second side of the welding rod.

Abstract: A welding electrode comprising a metal core and a coating material that includes flux compounds is at least partially coated on an outer surface of said metal core. The tip of the welding electrode is beveled and a portion of the beveled tip has an end coating material which includes an electrically-conductive material.

Abstract: The hybrid wire of the present invention comprises approximately 1% Wt to 30% Wt of non-metallic ingredients, with the preferred concentrations selected from the range from about 5% Wt to about 15% Wt. Non-metallic compounds and metallic oxides, which were added to the tubular wires and found to perform well in the SAW process, are CaO, MgO, MgAl, K2O, CaF2, MnO, NaAlF6, and K2AlF6. Adding one or more of the listed compounds to the core composition of the tubular wires leads to an improvement of the welding performance in a SAW process due to the properties of core of the wire, while reducing the importance of the granular flux.

Abstract: A chromium-free welding consumable and a method of welding stainless steel to reduce the presence of chromium emissions. The consumable is made from an alloy that reduces the emission of chromium during a welding process, and include predominantly nickel, with between approximately five and ten weight percent copper, up to approximately two percent by weight of ruthenium and up to five percent non-copper alloying ingredients. Welding consumables made from the alloy are particularly well-suited for welding austenitic stainless steels, such as type 304 stainless steel. The method involves using chromium-free weld filler material with a stainless steel base material.

Abstract: A self-shielding welding electrode and a method of making the same are provided. The self-shielding welding electrode contains rare earth aluminide in either the flux or the electrode portion of the electrode. The self-shielding welding electrode contains at least about 0.5% by weight of the flux of rare earth aluminide.

Abstract: In a rotary electric machine, at least one of first and second ends of each conductor segment is at least partially joined to at least one of the first and second ends of a corresponding another one of the conductor segments to provide the stator winding including a plurality of joint portions of the plurality of conductor segments. An insulating film covers each of the conductor segments except for at least the joint portions of the stator winding. At least part of the insulating film of each of the conductor segments located close to a corresponding one of the joint portions contains an evaporatable component. An amount in ppm of the evaporatable component contained in the at least part of the insulating film is adjusted to be equal to or lower than 20000 ppm.

Abstract: A welding electrode comprising a metal core and a flux coating at least partially coated on an outer surface of said metal core, and also including a end coating material which at least partially inhibits porosity of a weld bead formed during the welding operation.

Abstract: A continuous welding electrode suitable for short circuit welding is provided. The electrode has a continuous metal core with a welding flux material coated on its entire outer surface and circumscribing gaps are formed at regular interval over its entire length to expose a portion of the metal core. The gaps are adaptable for applying the welding current to the electrode in the welding operation. The melting temperature of the welding flux material is about 0.8 to 0.9 times the melting temperature of the metal core; and the unit weight of the welding flux material coating is about 0.37 to 0.48 times the unit weight of the metal core.

Abstract: A filler wire for laser-welding an aluminum alloy is described, which comprises a base material of Aluminum-Silicon based alloy and a flux of Aluminum-Potassium-Fluorine-based composition. The amount of the flux in the base material is greater than 0 (zero) wt. % and less than approximately 1.0 wt. %.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and having an indented and non-indented region with the cross sectional area of the solid metal at said non-indented region being greater than the cross sectional area of the solid metal at the indented region.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and joined together by interconnecting bridging elements with the cross sectional area of the solid metal at said segments being greater than the cross sectional area of the solid metal at the bridging elements.

Abstract: A nickel, chromium, iron alloy for use in producing weld deposits. The alloy comprises, in weight percent, about 27 to 31.5 chromium; about 7 to 11 iron; about 0.005 to 0.05 carbon; less than about 1.0 manganese, preferably 0.30 to 0.95 manganese; about 0.60 to 0.95 niobium; less than 0.50 silicon, preferably 0.10 to 0.30 silicon; 0.01 to 0.35 titanium; 0.01 to 0.25 aluminum; less than 0.20 copper; less than 1.0 tungsten; less than 1.0 molybdenum; less than 0.12 cobalt; less than 0.10 tantalum; less than about 0.10 zirconium, preferably 0.002 to 0.10 zirconium; less than about 0.01 sulfur; less than about 0.01 boron, preferably 0.001 to 0.01 boron; less than about 0.02 phosphorous; and balance nickel and incidental impurities.

Abstract: A welding wire for use in electric arc welding and method of making same, wherein the wire has an effective outer diameter and comprises a length of solid metal formed into a series of distinct segments each having a selected volume and having an indented and non-indented region with the cross sectional area of the solid metal at said non-indented region being greater than the cross sectional area of the solid metal at the indented region.