Abstract: A system and method for submerged arc welding. The system advances a consumable welding electrode toward a workpiece, and then stops the advancement when the consumable electrode makes contact with the workpiece. The system provides a preheating current level through the consumable welding electrode proximate the workpiece while the consumable welding electrode is in contact with the workpiece during a preheating period of time to preheat the portion of the consumable welding electrode without establishing an arc. The system then retracts the consumable welding electrode from the workpiece and increases the preheating current level to a welding current level over an arc establishment period of time to establish an arc between the consumable welding electrode and the workpiece. The system then begins to form a weld by advancing the consumable welding electrode toward the workpiece again, resulting in melting the consumable welding electrode and depositing molten metal onto the workpiece.

Abstract: A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.

Abstract: A regulating valve device for a fluid cylinder includes a shut off valve having a ball tappet that actuates the shut off valve. A lever has a cam surface that interacts with the ball tappet as the lever is rotated to translate the ball tappet linearly and actuate the shut off valve. The lever is rotatable from a first valve closed position through a valve open position to a second valve closed position such that the valve open position is intermediate of the first and second valve closed positions. A pressure or flow regulating valve is downstream of the shut off valve. A handwheel is operatively connected to the pressure or flow regulating valve to adjust an outlet pressure of the pressure or flow regulating valve. The handwheel has an axis of operation that is offset from a longitudinal axis of the fluid cylinder by an acute angle.

Abstract: An embodiment includes a robotic welding system for generating a motion program, having a programmable robot controller of a robot having a computer processor and a computer memory. The programmable robot controller is configured to digitally record, in the computer memory, a plurality of spatial points along an operator path in a 3D space taken by a calibrated tool center point (TCP) of the robot as an operator manually moves a robot arm of the robot along the operator path from a start point to a destination point within the 3D space. The programmable robot controller is also configured to identify and eliminate extraneous spatial points from the plurality of spatial points as digitally recorded, leaving a subset of the plurality of spatial points as digitally recorded, where the extraneous spatial points are a result of extraneous movements of the robot arm by the operator.

Abstract: An arc welding system providing improved molten metal droplet transfer. The system includes a welding power source having a welding power supply, a welding waveform generator, and a controller. Two fluxed cored welding wire electrodes are connected to the power source and are powered by the same welding output voltage and current produced by the power source. A feedback circuit is connected to the power source to provide an adaptive response to maintain an average welding output voltage. The controller controls the waveform generator and the power supply to superimpose welding current pulses onto a welding waveform of a CV flux cored arc welding process, that uses CO2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process. The current pulses are superimposed in time to form molten metal droplets between ends of the two electrodes during the modified welding process.

Abstract: A plasma cutting system includes a power supply that outputs first and second plasma cutting currents. A torch is connected to the power supply and includes a first cathode that receives the first plasma cutting current, a first electrode and swirl ring, a second cathode that receives the second plasma cutting current, and a second electrode and swirl ring. The torch simultaneously generates a first and second plasma arcs from the electrodes. A gas controller is configured to separately control a flow of a first plasma gas to the first swirl ring and a flow of a second plasma gas flow to the second swirl ring. A torch actuator moves the torch during cutting, and includes a motor having a hollow shaft rotor for rotating the torch during cutting. A motion controller is operatively connected to the torch actuator to control movements of the torch during cutting.

Abstract: A real-time virtual reality welding system including a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of importing data into the virtual reality welding system and analyzing the data to characterize a student welder's progress and to provide training.

Abstract: A welding system can include a carriage having a top surface and a bottom surface. A first set of wheels can be coupled to the top surface of the carriage, and a second set of wheels can be coupled to the top surface of the carriage, spaced apart from the first set of wheels to create a first beam channel. The welding system can further include a first beam that includes a rack extending along a side of the first beam. The first beam can extend through the first beam channel and engage with the first and second sets of wheels. The welding system can further include a first positioning motor that includes a pinion gear. The first positioning motor is removeably coupled to the carriage such that the pinion gear is positioned to engage the rack extending along the first beam.

Abstract: The disclosed technology relates generally to welding, and more particularly to consumable electrodes based on aluminum and methods of welding using the same. In one aspect, a consumable welding electrode comprises a base metal composition comprising at least 70% by weight of aluminum and a fluidity-enhancing metal capable of forming a binary eutectic with aluminum, wherein the binary eutectic undergoes a binary eutectic solidification at a eutectic temperature of 595-660° C. The fluidity-enhancing metal is present in form and a hypoeutectic concentration of 0.05-0.5 weight % such that a solidification temperature range of a molten weld metal formed by melting the consumable welding electrode is less than 65° C.

Abstract: A plasma arc torch includes a cathode extending along an axis of the torch, a pilot arc conductor, and a nozzle body. A first fluid conduit and second fluid conduit extend parallel to the axis of the torch. A first offset fitting includes a first duct coupled to and in fluid communication with the first fluid conduit, and a second duct in fluid communication with the first duct and outwardly radially offset from the first duct and extending away from the first duct in a proximal direction. A second offset fitting includes a third duct coupled to and in fluid communication with the second fluid conduit, and a fourth duct in fluid communication with the third duct and outwardly radially offset from the third duct and extending away from the third duct in the proximal direction. A spring compression plug electrically connects the pilot arc conductor to the nozzle body.