Abstract: The present disclosure is generally directed to a high temperature lubricant for use in a preheated welding wire system. The lubricant may comprise one or more high melting point materials in a concentration from 0.5 to 30 wt % by weight of the lubricant. The high melting point materials may comprise graphite, molybdenum disulfide, tungsten disulfide, or boron nitride. The lubricant is configured to remain on a welding wire electrode that has been coated with the lubricant without melting when a preheater heats the welding wire electrode to an elevated temperature (e.g., between 500 and 900 degrees Celsius). The lubricant may be a powder or a liquid. When the lubricant is a liquid, it may further comprise a solvent such as 2-proponal or water.

Abstract: Present embodiments include systems and methods for stick welding applications. In certain embodiments, simulation stick welding electrode holders may include stick electrode retraction assemblies configured to mechanically retract a simulation stick electrode toward the stick electrode retraction assembly to simulate consumption of the simulation stick electrode during a simulated stick welding process. In addition, in certain embodiments, stick welding electrode holders may include various input and output elements that enable, for example, control inputs to be input via the stick welding electrode holders, and operational statuses to be output via the stick welding electrode holders. Furthermore, in certain embodiments, a welding training system interface may be used to facilitate communication and cooperation of various stick welding electrode holders with a welding training system.

Abstract: Systems and methods for tracking and associating welding-type data with selected welding jobs. A welding job from a plurality of welding jobs stored in memory of a welding-type power supply may be selected, and welding-type data collected while a particular welding jobs is selected is associated in memory with the selected welding job. Welding-type data associated with the plurality of welding jobs may be displayed and managed.

Abstract: Present embodiments include systems and methods for stick welding applications. In certain embodiments, simulation stick welding electrode holders may include stick electrode retraction assemblies configured to mechanically retract a simulation stick electrode toward the stick electrode retraction assembly to simulate consumption of the simulation stick electrode during a simulated stick welding process. In addition, in certain embodiments, stick welding electrode holders may include various input and output elements that enable, for example, control inputs to be input via the stick welding electrode holders, and operational statuses to be output via the stick welding electrode holders. Furthermore, in certain embodiments, a welding training system interface may be used to facilitate communication and cooperation of various stick welding electrode holders with a welding training system.

Abstract: Present embodiments include systems and methods for stick welding applications. In certain embodiments, simulation stick welding electrode holders may include stick electrode retraction assemblies configured to mechanically retract a simulation stick electrode toward the stick electrode retraction assembly to simulate consumption of the simulation stick electrode during a simulated stick welding process. In addition, in certain embodiments, stick welding electrode holders may include various input and output elements that enable, for example, control inputs to be input via the stick welding electrode holders, and operational statuses to be output via the stick welding electrode holders. Furthermore, in certain embodiments, a welding training system interface may be used to facilitate communication and cooperation of various stick welding electrode holders with a welding training system.

Abstract: Systems, methods, and apparatus to reduce cast in a welding wire are disclosed. Example systems to reduce cast in a welding wire include a wire advancement roller configured to advance welding wire from a welding wire supply toward a welding torch; and a wire straightener configured to reduce cast in the welding wire by applying heat to the welding wire between the welding wire supply and the welding torch.

Abstract: Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding assembly for a welding torch includes: a first contact tip configured to conduct welding current to a consumable electrode; a second contact tip configured to conduct preheating current to the consumable electrode; and a cooling body configured to transfer heat from at least the first contact tip to coolant and to conduct the welding current.

Abstract: Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.

Abstract: Systems, methods, and apparatus to control welding electrode preheating are disclosed. An example consumable electrode-fed welding-type system includes a welding-type current 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; an electrode preheating circuit configured to provide preheating current through a first portion of the welding-type electrode via a second contact tip of the welding torch; an electrode preheating control circuit configured to adjust at least one of the preheating current or an electrode feed speed based on the change in the contact-tip-to-work-distance; and a current interpreter configured to determine a change in a contact-tip-to-work-distance of the welding torch based on at least one of the welding-type current or the preheating current.

Abstract: Systems, methods, and apparatus to preheat welding wire for low hydrogen welding are disclosed. An example apparatus to reduce hydrogen associated with a consumable welding electrode includes: 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; an electrode preheating circuit configured to provide preheating current through a first portion of the welding-type electrode between a wire feeder supplying the welding-type electrode and at least one of the first contact tip or a second contact tip of the welding torch.

Abstract: Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.