Abstract: A robotic electric arc welding system includes a welding torch, a welding robot configured to manipulate the welding torch during a welding operation, a robot controller operatively connected to the welding robot to control weaving movements of the welding torch along a weld seam and at a weave frequency and weave period, and a welding power supply operatively connected to the welding torch to control a welding waveform, and operatively connected to the robot controller for communication therewith. The welding power supply is configured to sample a plurality of weld parameters during a sampling period of the welding operation and form an analysis packet, and process the analysis packet to generate a weld quality score, wherein the welding power supply obtains the weave frequency or the weave period and automatically adjusts the sampling period for forming the analysis packet based on the weave frequency or the weave period.

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: Embodiments of welding work cells are disclosed. One embodiment includes a workpiece positioning system, a welding power source, and a welding job sequencer. The workpiece positioning system powers an elevating motion and a rotational motion of a workpiece mounted between a headstock and a tailstock to re-position the workpiece for a next weld to be performed. The welding power source generates welding output power based on a set of welding parameters of the power source. The welding job sequencer commands the workpiece positioning system to re-position the workpiece from a current position to a next position in accordance with a next step of a welding sequence of a welding schedule. The welding job sequencer also commands the welding power source to adjust a current set of welding parameters to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule.

Abstract: A spool has a first flange and a second flange. A barrel extends between the first flange and the second flange. A movable hub is located radially inward of the barrel. The barrel is axially wider than the movable hub and the movable hub is axially movable between a first operational position adjacent the first flange and a second operational position adjacent the second flange. The movable hub includes an axially-extending cantilevered detent arm forming a stop surface that limits axial movement of the movable hub toward one of the first flange and the second flange.

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 or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing system includes a power supply having a controller which controls operation of the power supply. The power supply provides a current waveform to a contact tip assembly having a first bore terminating at a first exit orifice and a second bore terminating at a second exit orifice. The first exit orifice is configured to deliver a first wire electrode and said second exit orifice is configured to deliver a second wire electrode. The exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between the wire electrodes while preventing solid portions of the first wire electrode delivered through the first bore from contacting solid portions of the second wire electrode delivered through the second bore, during a deposition operation in which the current waveform is conducted to both of the wire electrodes simultaneously through the contact tip assembly.

Abstract: A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Abstract: A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.

Abstract: Welding training systems and methods utilize a welding simulator wherein multiple users can interact simultaneously with distinct simulated environments or within the same simulated environment.

Abstract: A quick connect refill friction stir spot welding tool includes a clamp having a first radially-projecting mounting tab configured for engaging a first mounting slot in a refill friction stir spot welding weld head. A friction sleeve is located coaxially within the clamp and has a second radially-projecting mounting tab configured for engaging a second mounting slot in the refill friction stir spot welding weld head. The second radially-projecting mounting tab is located higher along an axis of the tool than the first radially-projecting mounting tab, and radially inward thereof. A friction pin is located coaxially within the clamp and friction sleeve. The clamp and friction sleeve are attachable to and detachable from the refill friction stir spot welding weld head by rotations through less than 360 degrees.

Abstract: A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

Abstract: A welding or cutting system having a power supply with no user interface hardware or software for controlling the operation of the power supply, and a mobile communication device which contains an application allowing for control of the power supply. The mobile device is coupled to the power supply through either a wired or wireless connection.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: The disclosed technology generally relates welding electrodes, and more particularly to covered consumable welding electrodes. In an aspect, a consumable welding electrode comprises a core wire comprising a steel composition and a coating formed on the core wire. The coating comprises weld metal alloying elements comprising Fe, C, Mn, Si, Ni, Mo, V and Cr that are arranged such that an undiluted weld metal formed from the covered welding electrode has a combination of high tensile strength and high impact strength.

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.