Abstract: A modular and reconfigurable chassis enables minimalization of inventory while facilitating ease of conversion into multiple configurations of a welding simulator. The modular and reconfigurable chassis permits both hardware and software related system configurations. The chassis is adapted to receive hardware interfaces for single and multiple user configurations.

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 diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A system for aiding a user in at least one of welding, cutting, joining, and cladding operations is provided. The system includes a welding tool and a welding helmet with a face-mounted display. The system also includes a spatial tracker configured to track the welding helmet and the welding tool in 3-D space relative to an object to be worked on. A processor based subsystem is configured to generate visual cues based on information from the spatial tracker and transmit the visual cues to a predetermined location on the face-mounted display.

Abstract: A system for aiding a user in at least one of welding, cutting, joining, and cladding operations is provided. The system includes a welding tool and a welding helmet with a face-mounted display. The system also includes a spatial tracker configured to track the welding helmet and the welding tool in 3-D space relative to an object to be worked on. A processor based subsystem is configured to generate virtual objects based on objects found in a welding environment and transmit the virtual objects to a predetermined location on the face-mounted display.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A welding simulator which facilitates simulated welding training on a complex structure. The simulator may receive CAD or actual measurement data for components forming the structure and use the data to generate digital models of the components for display or analysis activities. The simulator may enable simulated testing of the complex structure and calculate performance measures using the results of the simulated testing. The simulator may allow a user to repeat a simulated weld until a desired score is achieved and store data collected during the simulated weld for later use.

Abstract: A modular and reconfigurable chassis enables minimalization of inventory while facilitating ease of conversion into multiple configurations of a welding simulator. The modular and reconfigurable chassis permits both hardware and software related system configurations. The chassis is adapted to receive hardware interfaces for single and multiple user configurations.

Abstract: Welding training systems and methods utilize gaming concepts to encourage user participation and focus. The system sand methods can also manage competitive activities amongst multiple users.

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 diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A system for aiding a user in at least one of welding, cutting, joining, and cladding operations is provided. The system includes a welding tool and a welding helmet with a face-mounted display. The system also includes a spatial tracker configured to track the welding helmet and the welding tool in 3-D space relative to an object to be worked on. A processor based subsystem is configured to generate visual cues based on information from the spatial tracker and transmit the visual cues to a predetermined location on the face-mounted display.

Abstract: A system for aiding a user in at least one of welding, cutting, joining, and cladding operations is provided. The system includes a welding tool and a welding helmet with a face-mounted display. The system also includes a spatial tracker configured to track the welding helmet and the welding tool in 3-D space relative to an object to be worked on. A processor based subsystem is configured to generate virtual objects based on objects found in a welding environment and transmit the virtual objects to a predetermined location on the face-mounted display.

Abstract: A system and method for calibrating a welding training apparatus. The system includes reference markers disposed in a 3-D space of a welding environment so as to have a known fixed orientation in the 3-D space of the welding environment. An image capturing device scans the welding environment, which includes a welding coupon or a workpiece. The image capturing device also captures an image of the welding environment. An object recognition device automatically identifies the welding coupon or the workpiece in the captured image and automatically associates a weld path to the identified welding coupon or workpiece. A calibration device automatically calibrates the welding training apparatus by correlating the weld path to the 3-D space of the welding environment based on the reference markers.

Abstract: A welding training system for at least one of welding, cutting, joining, and cladding operations is provided. The system includes a welding tool and a welding power supply. The system also includes a processor based subsystem configured to execute welding training software that monitors a performance of a user based on a position, orientation and movement of the welding tool as the user performs a real-world weld. The processor-based subsystem is also configured to communicate with the power supply to receive at least one of a welding mode, welding current and a welding voltage. The system also includes a user interface that is operatively connected to the processor-based subsystem such that the user can setup, view and modify settings of the power supply via the processor based subsystem.

Abstract: A welding diffuser and contact tip assembly is provided for use with a welding apparatus. The assembly includes a diffuser with an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser, and a contact tip coupled to the diffuser. The contact tip includes a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an angled outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to thereby discharge the debris to an exterior of the diffuser. In one example, the rear portion of the contact tip includes an angled outer surface defining the diffuser insert.

Abstract: A diffuser insert is provided for use with a welding diffuser and contact tip assembly comprising a diffuser with an interior chamber configured to receive a wire conduit that supplies electrode wire and a shielding gas used during a welding operation and a contact tip coupled to the diffuser and configured to receive electrode wire. The diffuser insert comprises a diffuser insert body configured to be disposed within the interior chamber of the diffuser, and further comprises an insert bore extending therethrough configured to receive electrode wire. An outer periphery of the diffuser insert has at least one surface feature configured to manipulate a flow of said shielding gas from within said interior chamber of the diffuser and out of exit passages to thereby direct said flow of shielding gas about a molten welding puddle formed during a welding operation.

Abstract: A welding gun includes a handle portion comprising a motor configured to move electrode wire through the welding gun. A diffuser comprises an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser. A barrel is located between the diffuser and the handle portion and supplies to the diffuser from the handle portion. A contact tip extends from the diffuser and comprises a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive the electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to discharge the debris. The handle portion is configured to direct a flow of the shielding gas over the motor to cool the motor.