Abstract: An embodiment includes a welding system for performing an automatic GMAW welding process. The welding system provides a welding contact tip configured to be attached to a welding tool. The contact tip is configured to accept a consumable welding wire electrode that is fed there-through during the automatic GMAW welding process to form an arc between a tip of the consumable welding wire electrode and a work piece. A secondary material, being of a different material from that of the welding contact tip, is positioned at or near a distal end of the welding contact tip. During the automatic GMAW welding process, detection of a flaring event of the arc by the welding system is facilitated by the secondary material changing phase in response to the flaring event, resulting in changing at least one detectable characteristic of the arc.

Abstract: An embodiment includes an apparatus for supporting automatic welding performed by a welding system. A welding contact tip is configured to be attached to a welding tool and is configured to accept a consumable welding wire electrode that is fed there-through during an automatic GMAW welding process to form an arc between a tip of the consumable welding wire electrode and a work piece. A secondary material, being of a different material from that of the welding contact tip, is positioned at or near a distal end of the welding contact tip. During the automatic GMAW welding process, detection of a flaring event of the arc by the welding system is facilitated by the secondary material changing phase in response to the flaring event, resulting in changing at least one detectable characteristic of the arc.

Abstract: Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.

Abstract: A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Abstract: Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

Abstract: A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: A method of preventing arc flaring events for a welding system is provided. The method includes determining, by a controller, a real-time welding output characteristic of the welding system. The method additionally includes comparing, by the controller, the real-time welding output characteristic to a threshold welding output characteristic. The method further includes controlling an operating characteristic of the welding system in response to a determination that the real-time welding output characteristic exceeds the threshold welding output characteristic.

Abstract: A system for controlling arc length by regulating short circuit events during a welding process includes a welding power supply configured to conduct a free flight transfer pulsed arc welding process between a welding electrode and a workpiece, and a controller operatively connected to the welding power supply to control a welding waveform of the free flight transfer pulsed arc welding process. The controller is configured to automatically determine whether or not tethered incipient short circuits are included in said welding waveform, monitor a short circuit event characteristic during the free flight transfer pulsed arc welding process, and automatically adjust, based on said short circuit event characteristic, at least one parameter of said welding waveform to regulate tethered incipient short circuiting of the welding electrode to the workpiece during the free flight transfer pulsed arc welding process after determining that tethered incipient short circuits are included in said welding waveform.

Abstract: A welding system includes a power supply configured to output a series of welding waveforms for generating a welding current in a consumable welding electrode, and a wire feeder that advances the electrode toward a weld puddle during a welding operation. The wire feeder includes a subcircuit having a switching device and parallel resistance, the subcircuit being connected in series with the electrode such that the welding current flows through the subcircuit. The switching device is controllable between conducting and nonconducting states. The wire feeder includes a controller operatively connected to the switching device that controls switching operations of the switching device. The power supply is configured to remotely identify occurrences of the switching operations in the wire feeder and control the welding waveforms based on the occurrences of the switching operations.

Abstract: The invention described herein generally pertains to a system and method related to reducing magnetic arc blow during a welding operation performed by a welding system. In accordance with one embodiment of the invention, a welding system including a waveform generator generates a waveform that is switched from a positive current to a negative current, while passing through zero, in a step-wise fashion to resist the magnetic field within the material (e.g., the workpiece). In accordance of another embodiment of the invention, the welding system includes a nickel flux cord welding wire.

Abstract: A welding system includes a consumable welding electrode, a feeder that advances the consumable welding electrode toward a weld puddle during a welding operation, and a power supply configured to provide a series of welding waveforms to the consumable welding electrode to generate a welding current in the consumable welding electrode. An individual welding waveform of said series includes a predetermined minimum current portion, a peak current portion, and a background current portion having a magnitude that is greater than the minimum current portion and less than the peak current portion. The power supply comprises an adjustable resistance for setting a magnitude of the minimum current portion. The adjustable resistance is connected in series with the consumable welding electrode such that the minimum current portion of the welding current flows through the adjustable resistance.

Abstract: Systems and methods for facilitating the starting and stopping of arc welding processes, as well as for responding to events in mid-weld. Specially designed signals may be briefly applied between a welding electrode and a welding workpiece at the start and end of a welding process to gracefully and properly start and stop a weld. Furthermore, specially designed signals may be briefly applied in the middle of a welding process, if determined events occur, to counter the undesirable effects of the events.

Abstract: The invention described herein generally pertains to a system and method related to reducing magnetic arc blow during a welding operation performed by a welding system. In accordance with one embodiment of the invention, a welding system including a waveform generator generates a waveform that is switched from a positive current to a negative current, while passing through zero, in a step-wise fashion to resist the magnetic field within the material (e.g., the workpiece). In accordance of another embodiment of the invention, the welding system includes a nickel flux cord welding wire.

Abstract: Systems and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance.

Abstract: Systems and methods for facilitating the starting and stopping of arc welding processes, as well as for responding to events in mid-weld. Specially designed signals may be briefly applied between a welding electrode and a welding workpiece at the start and end of a welding process to gracefully and properly start and stop a weld. Furthermore, specially designed signals may be briefly applied in the middle of a welding process, if determined events occur, to counter the undesirable effects of the events.

Abstract: Systems and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance.