Abstract: A method of controlling highly regulated power and frequency from a high frequency power supply system to provide a highly regulated power and frequency to a workpiece load where the highly regulated power and frequency can be independent of the workpiece load characteristics by inverter switching control and an inverter output impedance adjusting and frequency control network that can include precision variable reactor pairs with a geometrically-shaped moveable insert core section and a stationary split-bus section with a complementary geometrically-shaped split bus section and a split electric terminal bus section where the insert core section can be moved relative to the stationary split-bus section to vary the inductance of the variable reactors.

Abstract: A solenoidal induction coil with dynamically variable coil geometry is provided for inductively welding or heating continuous or discontinuous workpieces passing through the solenoidal induction coil in a process line. The coil geometry can change, for example, as the outer dimension of the workpiece passing through the solenoidal induction coil changes or as non-continuous workpieces pass through the solenoidal induction coil in an induction heating or welding process line.

Abstract: A high frequency power supply system provides highly regulated power and frequency to a workpiece load where the highly regulated power and frequency can be independent of the workpiece load characteristics by inverter switching control and an inverter output impedance adjusting and frequency control network that can include precision variable reactors with a geometrically-shaped moveable insert core section and a stationary split-bus section with a complementary geometrically-shaped split bus section and split electric terminal bus section where the insert core section can be moved relative to the stationary split-bus section to vary the inductance of the variable reactors.

Abstract: A solenoidal induction coil with dynamically variable coil geometry is provided for inductively welding or heating continuous or discontinuous workpieces passing through the solenoidal induction coil in a process line. The coil geometry can change, for example, as the outer dimension of the workpiece passing through the solenoidal induction coil changes or as non-continuous workpieces pass through the solenoidal induction coil in an induction heating or welding process line.

Abstract: High frequency electrical heating system is provided for heating electrically conductive parts as they are advanced, either for annealing or welding processes, and in which the electrical heating current is supplied by a solid state DC to AC inverter through a load matching and frequency control circuit that maintains the desired load current and frequency with changes in the load impedance caused by the electrically conductive parts as they are advanced. Load matching is achieved with high frequency variable reactors having a geometrically-shaped moveable insert core section and a stationary split-bus section with a complementary geometrically-shaped split bus section and a split electric terminal bus section where the insert core section can be moved relative to the stationary split-bus section to vary the inductance of the reactor pair.

Abstract: A series of time-sequenced heat energy data arrays or data stream sets of a weld process region are processed by a weld data array or data stream processing system to produce a heat energy data set output that is related to weld process region features or weld process region heat energy data. The heat energy data set output can be displayed to a system user and modified by system user input to the weld data array or data stream processing system; alternatively, or in combination, the system user output and input, the heat energy data set output, or data produced from the heat energy data set output by the weld data array or data stream processing system, can be transmitted to a weld process controller to adjust parameters in the weld process responsive to the output of the weld data array or data stream processing system.

Abstract: A solenoidal induction coil with dynamically variable coil geometry is provided for inductively welding or heating continuous or discontinuous workpieces passing through the solenoidal induction coil in a process line. The coil geometry can change, for example, as the outer dimension of the workpiece passing through the solenoidal induction coil changes or as non-continuous workpieces pass through the solenoidal induction coil in an induction heating or welding process line.

Abstract: A spray quench system is provided with one or more spray quench rings that eject a controlled volume of quenchant spray onto a workpiece passing through the quench rings. Supply of the quenchant to the quench rings is coordinated with control of the quench rings to selectively change the pressure, quenchant spray exit velocity from the quench rings, flow rate or pattern of the quenchant spray onto the workpiece depending upon mass cooling requirements as the workpiece passes through the quench rings.

Abstract: A method of quenching a workpiece is provided with one or more spray quench rings that eject a controlled variable volume of spray quench onto a workpiece passing through the quench rings by dynamically adjusting the axially adjustable distance between the inner and outer ring elements of each quench ring while the workpiece passes through the quench rings in response to mass cooling requirements of the workpiece passing through the quench rings. The quench rings can also be axial adjusted relative to each other in response to the mass cooling requirements. Dynamically adjustable reflected spray guards can be provided to prevent quench spray pattern interference between adjacent quench rings.

Abstract: A solenoidal induction coil with dynamically variable coil geometry is provided for inductively welding or heating continuous or discontinuous workpieces passing through the solenoidal induction coil in a process line. The coil geometry can change, for example, as the outer dimension of the workpiece passing through the solenoidal induction coil changes or as non-continuous workpieces pass through the solenoidal induction coil in an induction heating or welding process line.

Abstract: A spray quench system is provided with one or more spray quench rings that eject a controlled volume of quenchant spray onto a workpiece passing through the quench rings. Supply of the quenchant to the quench rings is coordinated with control of the quench rings to selectively change the pressure, quenchant spray exit velocity from the quench rings, flow rate or pattern of the quenchant spray onto the workpiece depending upon mass cooling requirements as the workpiece passes through the quench rings.

Abstract: A method of quenching a workpiece is provided with one or more spray quench rings that eject a controlled variable volume of spray quench onto a workpiece passing through the quench rings by dynamically adjusting the axially adjustable distance between the inner and outer ring elements of each quench ring while the workpiece passes through the quench rings in response to mass cooling requirements of the workpiece passing through the quench rings. The quench rings can also be axial adjusted relative to each other in response to the mass cooling requirements. Dynamically adjustable reflected spray guards can be provided to prevent quench spray pattern interference between adjacent quench rings.

Abstract: A method for setting the operating frequency of a forge welding machine for a preferred width of the of the heat affected zone during a forge weld. A computer program executes a self-tuning routine to determine the operating frequency in response to an inputted value of a preferred width of the heat affected zone. The operating power setting for the forge welding machine may also be determined in combination with the operating frequency in response to an inputted value of weld temperature.

Abstract: A method for setting the operating frequency of a forge welding machine for a preferred width of the of the heat affected zone during a forge weld. A computer program executes a self-tuning routine to determine the operating frequency in response to an inputted value of a preferred width of the heat affected zone. The operating power setting for the forge welding machine may also be determined in combination with the operating frequency in response to an inputted value of weld temperature.

Abstract: A system and method for computing the parameters of a forge welding machine for the forge welding of one or more materials is provided. A computer program executes a self-tuning routine to compute the operating frequency and operating power setting for the forge welding machine in response to an inputted width of the heat affected zone and an inputted weld temperature.

Abstract: A solid state switching circuit utilizes a transformer in series with the circuit's switching device by which energy initially stored in the primary of the transformer is recovered in resonant circuitry connected to the secondary of the transformer for transfer of the energy to the load when the switching device is not conducting.

Abstract: In high frequency welding apparatus in which high frequency electrical heating current is supplied to metal surfaces to be welded together by contacts engaging the metal which is advanced toward a weld point, the contacts engage the metal in advance of the weld point and have contact faces with downstream edges contacting the metal. The downstream edge of one of the contacts, or the downstream edges of the both of the contacts, is or are skewed with respect to the path or paths of the metal surfaces to be heated so that the downstream edge or edges extend at an acute angle of about 35.degree. to about 55 .degree. with respect to the path or paths of the metal surface or surfaces, the angle being intermediate the contacts and the weld point.

Abstract: High frequency reactors for interconnecting a high frequency electrical power source and a load which reactors include a pair of plates having opposite surfaces with a length and width and a thickness between the surfaces which is small relative to the length and width of the surfaces. The plates are disposed with opposing closely spaced surfaces insulated from each other, and each of the plates has longitudinally aligned first and second portions with one portion of one of the plates electrically insulated from another portion of the plates and conductively interconnected by a variable reactance with another portion of the plates.

Abstract: High frequency electrical heating apparatus in which metal parts are heated as they are advanced,either for annealing or forge welding purposes,and in which the electrical heating current is supplied by solid state D.C. to A.C. inverter through a load matching and frequency control circuit which maintains the desired load current and current frequency with changes in the load impedance caused by the metal parts as they are advanced.

Abstract: A method and apparatus in which edge portions of metal parts, the edge portions being disposed with opposed surfaces, are heated by high frequency electrical currents as the edge portions are advanced and brought together at a weld point. The electrical currents are induced in the edge portions in advance of the weld point by two induction coils, one at one side of the metal parts and the other at the other side of the metal parts, disposed and energized from a high frequency electrical source so that the electrical currents at the opposed surfaces flow in opposite directions at any given time and the currents induced by one coil add to the currents induced by the other coil.