Abstract: Systems and methods are disclosed that provides a helical wire for use in welding applications. A torch can be adapted to form the helical wire from a straight wire and to provide the helical wire as a consumable electrode in a welding or cladding application. The helical wire can be, for example, solid, tubular, or seamless tubular. The torch concurrently forms the helical wire and provides welding current for the welding or cladding application.

Abstract: A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

Abstract: An additive manufacturing system includes an additive manufacturing tool configured to supply a plurality of droplets to a part, a temperature control device configured to control a temperature of the part, and a controller configured to control the composition, formation, and application of each droplet to the plurality of droplets to the part independent from control of the temperature of the part via the temperature control device. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material.

Abstract: A contact tip assembly with a preheating tip comprises a welding-type power source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding-type electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.

Abstract: An example system includes: a hand-held welding tool that is manually placed in a welding position, wherein the hand-held welding tool is configured to be activated to cause a contact tip or a welding heat source to automatically move from a first position and to second position during a welding operation, and wherein a welding arc is automatically and repeatedly turned off and on while the contact tip or the welding heat source moves from the first position to the second position to make a plurality of welds between the first position and the second position, wherein, as a travel speed decreases, a time period between each arc on time increases to make equally spaced welds.

Abstract: Sensor assisted head mounted displays for welding are disclosed. Disclosed example head mounted devices include an optical sensor, an augmented reality controller, a graphics processing unit, and a semi-transparent display. The optical sensor collects an image of a weld environment. The augmented reality controller determines a simulated object to be presented in a field of view, a position in the field of view, and a perspective of the simulated object in the field of view. The graphics processing unit renders the simulated object based on the perspective to represent the simulated object being present in the field of view and in the weld environment. The display presents the rendered simulated object within the field of view based on the position. At least a portion of the weld environment is observable through the display and the lens when the display is presenting the rendered simulated object.

Abstract: Systems and methods for the manufacture of a solid wire using additive manufacturing techniques are disclosed. In one embodiment, a fine powdery material is sintered or melted or soldered or metallurgically bonded onto a metal strip substrate in a compacted solid form or a near-net shape (e.g., a near-net solid wire shape) before being turned into a final product through forming or drawing dies.

Abstract: Present embodiments include a system that includes a welding tool configured to receive a welding wire from a wire feeder, to receive welding power from a power source, and to supply the welding wire to a workpiece during a welding process. The system also includes a mechanical oscillation system configured to mechanically oscillate a structural component toward and away from the workpiece. The structural component is external to the wire feeder and the power source. The system further comprises control circuitry configured to control the welding power based on feedback relating to the welding process.

Abstract: Methods and apparatus to communicate via a weld cable are disclosed. An example welding-type power supply includes a power converter, a receiver circuit, and a controller. The power converter converts input power to welding-type power based on a weld voltage setpoint and to output the welding-type power via a weld circuit. The receiver circuit receives a communication via the weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit. The communication includes weld voltage feedback information measured at a device remote from the power supply while the current is flowing through the weld circuit. The controller controls the welding-type power output by the power converter according to a voltage feedback loop using the weld voltage feedback information to regulate a weld voltage at the remote device to the weld voltage setpoint.

Abstract: Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and determine whether an acceptable range of the welding-type operation is exceeded based on the total average instantaneous power and the duration of the welding-type operation.

Abstract: Hybrid manual and automated welding systems and methods are described. A hand-held welding tool is manually positioned to engage a workpiece. The hand-held welding tool includes a motion device that is configured to automatically move a contact tip or a welding heat source during a welding operation after a manual triggering. A welding arc is automatically and repeatedly turned off and on to make a string of overlapping and equally spaced spot welds while the contact tip or the welding heat source moves from the first position to the second position.

Abstract: Apparatuses, systems, and/or methods relate to a welding system that provides a field former for use in welding applications. The welding system includes a welding torch that includes one or more coil windings through which flows current that forms a magnetic field. The magnetic field is concentric to the tool center point. An arc is formed between the electrode and a workpiece. The magnetic field forces the arc in a center of the welding torch or the one or more coiled windings.

Abstract: A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

Abstract: Methods and apparatus to communicate via a weld cable are disclosed. An example weld circuit communications device includes a receiver circuit, a processor, and a local communications adapter. The receiver circuit to receive a communication via a weld circuit while current is flowing through the weld circuit or after the current has stopped flowing through the weld circuit, the communication including weld voltage feedback information measured at a device remote from a power supply and remote from the weld circuit communications device while the current is flowing through the weld circuit. The processor generates power supply control information based on the weld voltage feedback information. The local communications adapter transmits the power supply control information to control welding-type power output by a power converter to regulate a weld voltage to a weld voltage setpoint.

Abstract: Systems and methods for the manufacture of a solid wire using additive manufacturing techniques are disclosed. In one embodiment, a fine powdery material is sintered or melted or soldered or metallurgically bonded onto a metal strip substrate in a compacted solid form or a near-net shape (e.g., a near-net solid wire shape) before being turned into a final product through forming or drawing dies.

Abstract: In certain embodiments, a welding wire delivery system includes a non-rotational actuator configured to engage, disengage, and move welding wire. In certain embodiments, the welding wire delivery system includes a piezoelectric walk motor, a piezoelectric worm drive, a piezoelectric wave drive, a shape memory alloy, a solenoid piston, a linear actuator or motor, or a voice coil actuator.

Abstract: A contact tip assembly with a preheating tip comprises a welding power source configured to provide welding current to a welding circuit, the welding circuit comprising a welding electrode and a first contact tip of a welding torch. The assembly also includes an electrode preheating circuit configured to provide preheating current through a portion of the welding electrode via a second contact tip of the welding torch, and a voltage sense circuit to monitor a voltage drop across the two contact tips, and the electrode preheating circuit adjusts at least one of the first current or the preheating current based on the voltage drop.

Abstract: A welding method includes feeding a welding electrode axially from a welding torch, moving the welding electrode radially in a desired pattern with respect to a central axis of the welding torch by a motion control assembly within the welding torch, transmitting from control circuitry a signal corresponding to a position of the welding electrode relative to a weld joint or weld pool, advancing the welding torch or a workpiece to establish a weld, and transferring material from the welding electrode to a first location in an area of the weld pool. The welding electrode moves radially while feeding the welding electrode from the welding torch, the material from the welding electrode is transferred to the first location during a first cycle of the desired pattern, and the first location is controlled based at least in part on the signal.

Abstract: An additive manufacturing system includes an additive manufacturing tool configured to receive a plurality of metallic anchoring materials and to supply a plurality of droplets to a part, and a controller configured to independently control the composition, formation, and application of each droplet to the plurality of droplets to the part. The plurality of droplets is configured to build up the part. Each droplet of the plurality of droplets includes at least one metallic anchoring material of the plurality of metallic anchoring materials.

Abstract: Methods and apparatus to determine heat input to a weld are disclosed. An example welding-type power supply includes a power converter to convert input power to output welding-type power, and a controller configured to: during a welding-type operation, calculate average instantaneous power values of the welding-type operation for discrete, non-overlapping time periods by multiplying voltage measurements and corresponding current measurements; identify an end of the welding-type operation; determine a duration of the welding-type operation; calculate a total average instantaneous power of the welding-type operation based on the average instantaneous power values for the time periods and the duration of the welding-type operation; and output a first value representative of the total average instantaneous power and a second value representative of the duration of the welding-type operation.