Abstract: A system for and a method of controlling filler wire is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a filler wire controller configured to move the filler wire in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or an admixture of a bead formed by the molten puddle.

Abstract: A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

Abstract: A welding system including a power supply, a torch electrically connected to said power supply, a wire feeder that provides a welding consumable to the torch, a controller that communicates with a motor associated the wire feeder and the power supply. The controller obtains a wire feed speed of said motor as it accelerates from a run-in speed to a pre-set speed and controls the power supplied to the torch based on this wire feed speed to reduce stubbing or spattering during arc initiation.

Abstract: A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

Abstract: A system for and a method of controlling filler wire is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a filler wire controller configured to move the filler wire in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or an admixture of a bead formed by the molten puddle.

Abstract: A system for and a method of controlling filler wire is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a filler wire controller configured to move the filler wire in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or an admixture of a bead formed by the molten puddle.

Abstract: A system and method for use in brazing, cladding, building up, filling, overlaying, welding, and joining applications is provided. The system includes a first laser beam system which directs a first laser beam at a surface of at least one workpiece to create a molten puddle on the surface and a wire feeder which advances a consumable to the molten puddle so that the consumable contacts the molten puddle. The system also includes a power supply which outputs a heating signal and the heating signal is directed to the consumable to heat the consumable prior to the consumable entering the puddle. The system further includes a second laser beam system which directs a second laser beam at the consumable prior to the consumable entering the puddle and a controller which controls an output of each of the power supply and the second laser beam system.

Abstract: A system and method for using filler wire with embedded information is provided. The filler wire includes a sheath comprising a first filler material and a core that is defined by the sheath. The core includes a second filler material and at least one integrated circuit module. The at least one integrated circuit module includes at least information about the filler wire. In some embodiments, the at least one integrated circuit module is configured for at least one of read operations and write operations that are done using a remote device.

Abstract: A system and method for heating a filler wire (consumable) using a laser in brazing, cladding, building up, filling, overlaying, welding, and joining applications. The filler wire includes a first surface that absorbs energy from a laser beam and a second surface separated from said first surface by a thickness t that is in a range of 0.010 inch to 0.045 inch. A cross-sectional shape of the filler wire includes at least one bend toward the laser beam along a length of the cross-sectional shape. The cross-sectional shape has a projected width w that is in a range of 0.030 inch to 0.095 inch.

Abstract: A system for and a method of controlling filler wire is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a filler wire controller configured to move the filler wire in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or an admixture of a bead formed by the molten puddle.

Abstract: A system and method for removing material in a workpiece is provided. The system includes a laser system that melts a portion of the workpiece by heating the workpiece. The system includes a wire feeder system that feeds a wire to the workpiece to remove molten metal from the workpiece by using the wire. The wire is configured such that the molten metal adheres to the wire when the wire makes contact with the molten metal. The melting by the laser system includes a cutting or a gouging of the workpiece. In some embodiments, the system includes a hot wire power supply that supplies heating current through a length of the wire to heat the length of the wire to a desired temperature. The heating of the wire facilitates the adherence of the molten metal to the wire.

Abstract: A system and method for use in brazing, cladding, building up, filling, overlaying, welding, and joining applications is provided. The system includes a first laser beam system which directs a first laser beam at a surface of at least one workpiece to create a molten puddle on the surface and a wire feeder which advances a consumable to the molten puddle so that the consumable contacts the molten puddle. The system also includes a power supply which outputs a heating signal and the heating signal is directed to the consumable to heat the consumable prior to the consumable entering the puddle. The system further includes a second laser beam system which directs a second laser beam at the consumable prior to the consumable entering the puddle and a controller which controls an output of each of the power supply and the second laser beam system.

Abstract: A welding system including a power supply, a torch electrically connected to said power supply, a wire feeder that provides a welding consumable to the torch, a controller that communicates with a motor associated the wire feeder and the power supply. The controller obtains a wire feed speed of said motor as it accelerates from a run-in speed to a pre-set speed and controls the power supplied to the torch based on this wire feed speed to reduce stubbing or spattering during arc initiation.