Abstract: A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

Abstract: A welding torch includes a nozzle with a first welding wire guide configured to orient a first welding wire in a first welding wire orientation, and a second welding wire guide configured to orient a second welding wire in a second welding wire orientation that is non-coplanar and divergent with respect to the first welding wire orientation. A method of welding includes moving a welding torch with respect to a workpiece joint to be welded. During moving the welding torch, a first welding wire is fed through a first welding wire guide defining a first welding wire orientation and a second welding wire is fed through a second welding wire guide defining a second welding wire orientation that is divergent and non-coplanar with respect to the first welding wire orientation.

Abstract: A method and apparatus for monitoring quality of a weld bead during a welding process utilizing an electronic controller is disclosed. The method and apparatus includes determining an average power spectral density value for a first welding parameter signal between a first predetermined frequency and a second predetermined frequency, determining an average power spectral density value for a second welding parameter signal between a first predetermined frequency and a second predetermined frequency, and comparing the average power spectral density value for the second welding parameter signal with the average power spectral density value for the first welding parameter signal and terminating the welding process if the average power spectral density value for the first welding parameter signal exceeds the average power spectral density value for the second welding parameter signal.

Abstract: A welding apparatus includes a welding torch and a workpiece support. The welding apparatus also includes a circuit for creating a first voltage drop between the welding torch and the workpiece support so as to generate heat which melts a quantity of weld wire, the creating circuit having a power supply. The apparatus system further includes a power cable which is electrically interposed between the power supply and the welding torch. Additionally, the welding apparatus includes a circuit for measuring a second voltage drop across the power cable at the same time the first voltage drop is being created by the creating circuit. A method of operating a welding system is also disclosed.

Abstract: A method for sensing and controlling the weld quality of gas metal arc welding employs sampling of the welding current and voltage signals and making determinations of the weld quality state based on information embedded in those signals. The signals are processed such that the quality of the weld can be determined and the appropriate steps are taken to respond to the detected quality level. If the quality level is deemed unacceptable the process is terminated and the operator is alerted. The method includes determinations based on the standard deviation of the electrical signal, the summed power spectrum of the electrical signal, and/or the average absolute value of the time derivative of the electrical signal.

Abstract: A method for sensing and controlling the weld quality of gas metal arc welding employs sampling of the welding current and voltage signals and making determinations of the weld quality state based on information embedded in those signals. The signals are processed such that the quality of the weld can be determined and the appropriate steps are taken to respond to the detected quality level. If the quality level is deemed unacceptable the process is terminated and the operator is alerted. The method includes determinations based on the standard deviation of the electrical signal, the summed power spectrum of the electrical signal, and/or the average absolute value of the time derivative of the electrical signal.

Abstract: An automatic welder control 10 for direct and reverse polarity welding has an analog signal control circuit with an isolator 34 connected therein. This prevents the establishment of a circulating current path from the welder power drive circuit 14 through the signal circuit.