Abstract: Automatically identifying interchangeable torch components, such as consumables, for welding and cutting torches includes adding one or more passive markings to a surface of an interchangeable torch component. Then, automatic identification can be effectuated by a torch assembly including a torch body and one or more imaging devices or a system including the torch assembly and a power supply. The torch body has an operative end configured to removably receive one or more interchangeable torch components including one or more passive markings. The one or more imaging devices are positioned to optically acquire an image of or image data representative of the one or more passive markings included on the one or more interchangeable torch components so that the one or more interchangeable torch components can be automatically identified based on the one or more passive markings. Consequently, various components can be reliably and consistently identified.

Abstract: Approaches herein provide a plasma arc torch including a tip surrounding an electrode, the electrode having a proximal end and a distal end, and a shield surrounding the tip, the shield including an exit orifice proximate the distal end of the electrode. The torch may further include a linear actuating device coupled to the electrode for actuating the electrode such that the distal end of the electrode moves axially relative to the tip and the exit orifice of the shield. In some approaches, the linear actuating device is operable to actuate the electrode along a central longitudinal axis extending through the tip. In some approaches, the linear actuating device may include one of: a micro linear drive motor, a micro linear stepper motor, a voice coil, a solenoid coil, and a magnetostrictive actuator. In some approaches, the electrode is actuated during a welding or cutting cycle of the torch.

Abstract: A system, computer-implemented method, and article for controlling a user interface of a portable welding system are described. An input signal receiver, operable on a processor, is configured to receive one or more input signals from one or more input devices. A display controller, operable on the processor, is configured to receive, input information based upon the one or more input signals. A display device is configured to display a user interface provided by the display controller, the user interface including a first portion including an adjustable value and a second portion including a non-adjustable value. The display controller is configured to highlight changes to the non-adjustable value based upon changes made using the one or more input devices to the adjustable value.

Abstract: An automated oxy-fuel thermal processing system including an oxy-fuel torch, an automated machine tool operatively coupled to the torch for moving the torch relative to a work piece, and a circuit including a voltage source or a current electrically connected to the torch and configured to be electrically connected to the work piece. The automated oxy-fuel thermal processing system may further include a processor that is operatively connected to the torch, the automated machine tool, the circuit, and the voltage source or current source, wherein the processor is configured to control the operation of the torch, the automated machine tool and the voltage source or current source, and to monitor a current or voltage in the circuit in a predefined manner.

Abstract: A wire feeder including a housing having wire inlet and outlet regions. In some approaches, a tensioning assembly includes a pivotable tension arm and a pivotable tension knob assembly. The pivotable tension arm has a pivot axis oriented perpendicular to the direction of a wire fed through the wire feeder, while the pivotable tension knob assembly has a pivot axis oriented parallel to the direction of the wire fed through the wire feeder. A roller assembly includes a drive roller rotatably coupled to the pivotable tension arm, and a feed roller coupled to the housing. The feed roller is positionable opposite the drive roller to receive a welding wire therebetween and to move the welding wire from the wire inlet region to the wire outlet region. A gear assembly transmits rotational motion from a motor to the feed roller.

Abstract: A portable welding system casing includes front, rear, top and bottom portions. First and second side members can each have a plurality of fastening lug portions. The first and second side members may each have a recess so that the recess of the first side member receives a first perimeter edge of the front, rear, top and bottom portions and the recess of the second side member receives a second perimeter edge of the front, rear, top and bottom portions. A plurality of handle members can be coupled between associated fastening lug portions of the first and second side member. First and second foot members coupled to respective surfaces of the front, rear and bottom portions. The resulting casing has improved structural strength and rigidity.

Abstract: An apparatus may include a power supply to generate an output current. The apparatus may further include a plasma torch to apply the output current across a gap and a user interface to receive a selection for enabling a pierce current mode. The apparatus may further include a controller to temporarily increase an output current setting at the plasma torch from a first level to a second level, responsive to the selection of pierce current mode.

Abstract: A hybrid pressure and flowguage regulator apparatus includes a regulator body, an inlet, and an outlet assembly. The outlet assembly includes a first orifice of a first size, a second orifice of a second size that is larger than the first size, and a mechanism that automatically moves the first orifice between a first position and a second position. When the first orifice is in the first position, the flow of gas passes through both the first orifice and second orifice. When the first orifice is in the second position, the flow of gas bypasses the first orifice and flows through the second orifice with a specific flow rate or a second pressure that is less than the first pressure. The apparatus may also include a gauge that provides a visual indication of both the specific flow rate and the second pressure.

Abstract: A self-shielded flux cored arc welding electrode is disclosed including a ferrous metal sheath and a core within the sheath enclosing core ingredients comprise a composition window of aluminum, manganese and rare earth metals in wires of about 2.0-3.0 wt. % [Al], 1.0-2.0 wt. % [Mn] and 0.001-0.11 wt. % rare earth metals or 0.001-0.5% rare earth metal oxides, such as, but not limited to, La, Ce, etc. Resulting welds include 0.7-1.0 wt. % [Al] and 1.1-1.5 wt. % [Mn]. Resulting welds have a maximum diffusible hydrogen content of 5 mL/100 g or less, Resulting welds also have a Charpy V-notch toughness at ?40° F. of at least 100 ft-lbs.

Abstract: A system for dispensing weld wire comprises a container including walls and inside corners, a coil of weld wire within the container, and a de-coiling cone on the weld wire. The coil includes inner and outer circumferences, and the de-coiling cone includes an inner ring smaller than the inner circumference of the coil, an outer ring larger than the inner circumference and smaller than the outer circumference of the coil, and a plurality of legs extending radially outward from the inner ring to positions adjacent respective inside corners of the container. Each leg includes a first leg portion connecting the inner and outer rings, a second leg portion extending radially outwardly from the first leg portion, and a backwardly bent leg portion adjacent a corresponding inside corner of the container.

Abstract: A gas-shielded flux cored welding electrode comprises a ferrous metal sheath and a core within the sheath enclosing core ingredients. The core ingredients and sheath together comprise, in weight percentages based on the total weight of the core ingredients and the sheath: 0.25 to 1.50 manganese; 0.02 to 0.12 carbon; 0.003 to 0.02 boron; 0.2 to 1.5 silicon; 0 to 0.3 molybdenum; at least one of titanium, magnesium, and aluminum, wherein the total content of titanium, magnesium, and aluminum is 0.2 to 2.5; 3 to 12 titanium dioxide; at least one arc stabilizer, where the total content of arc stabilizers is 0.05 to 1.0; no greater than 10 of additional flux system components; remainder iron and incidental impurities.

Abstract: A system, computer-implemented method, and article for controlling a user interface of a portable welding system are described. An input signal receiver, operable on a processor, is configured to receive one or more input signals from one or more input devices. A display controller, operable on the processor, is configured to receive, input information based upon the one or more input signals. A display device is configured to display a user interface provided by the display controller, the user interface including a first portion including an adjustable value and a second portion including a non-adjustable value. The display controller is configured to highlight changes to the non-adjustable value based upon changes made using the one or more input devices to the adjustable value.

Abstract: A system for dispensing weld wire comprises a container including walls and inside corners, a coil of weld wire within the container, and a de-coiling cone on the weld wire. The coil includes inner and outer circumferences, and the de-coiling cone includes an inner ring smaller than the inner circumference of the coil, an outer ring larger than the inner circumference and smaller than the outer circumference of the coil, and a plurality of legs extending radially outward from the inner ring to positions adjacent respective inside corners of the container. Each leg includes a first leg portion connecting the inner and outer rings, a second leg portion extending radially outwardly from the first leg portion, and a backwardly bent leg portion adjacent a corresponding inside corner of the container.

Abstract: An automated oxy-fuel thermal processing system including an oxy-fuel torch, an automated machine tool operatively coupled to the torch for moving the torch relative to a work piece, and a circuit including a voltage source or a current electrically connected to the torch and configured to be electrically connected to the work piece. The automated oxy-fuel thermal processing system may further include a processor that is operatively connected to the torch, the automated machine tool, the circuit, and the voltage source or current source, wherein the processor is configured to control the operation of the torch, the automated machine tool and the voltage source or current source, and to monitor a current or voltage in the circuit in a predefined manner.

Abstract: An electrode is disclosed for use in MIG/MAG welding. The electrode comprises an elongated electrode body within which is embedded a metallic filament. In some embodiments, the filament is copper, and is offset from the center of the electrode body. A method is disclosed for forming an electrode. The method may include removing oxidation from a surface of an electrode body, forming the electrode body to a desired size and geometry, removing lubricants from the surface of the electrode body, forming an elongated channel in a surface of the electrode body, depositing a filament in the elongated channel, and forming the electrode body over the filament. Other embodiments are disclosed and claimed.

Abstract: A power supply, for a plasma cutter or a plasma arc welder, having a variable switching frequency and method of operating the power supply is generally disclosed. The power supply includes a switch for setting the switching frequency and a chopper control circuit for determining current output from the power supply, determining an operating frequency based on the determined current output and setting the switching frequency based on the determined operating frequency.

Abstract: A front end assembly for a plasma torch and methods for assembling and disassembling a torch wherein a plurality of front end parts form a unit that is removable from, and installable in, the torch in a single operation without a special fixture. The front end assembly includes a nozzle retaining cup body connectable to a body of the torch, and a forward end connectable to a shield retainer. A nozzle retaining cup insert fits into the nozzle retaining cup body. The shield retainer has an inner surface for retaining the shield. A nozzle is received within the nozzle retaining cup insert. A stop on the nozzle engages the nozzle retaining cup insert when the front end assembly is removed from the torch so the nozzle does not remain in the torch. The shield engages an insulator, which engages the nozzle, to limit forward axial movement of the nozzle.