Abstract: Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power 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 power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.

Abstract: An example contact tip for a welding torch includes: a first body section having a first diameter and exterior threads, the first body section having channels extending longitudinally along an exterior surface of the first body section to permit gas flow from a first end of the contact tip to a second end of the contact tip through the channels; a first bore portion having a first inner diameter; and a second bore portion having a second inner diameter configured to contact an electrode wire traveling through the second bore portion, the first inner diameter being larger than the second inner diameter.

Abstract: Submerged arc welding torches and systems to resistively preheat electrode wire are disclosed. A disclosed example submerged arc welding torch includes: a first contact tip configured to transfer weld current and preheating current to the wire; a second contact tip configured to conduct the preheating current to the wire; an air-cooled first conductive body portion configured to receive the weld current and to conduct the weld current and the preheating current to the first contact tip; an air-cooled second conductive body portion configured to receive the preheating current and to conduct the preheating current to the second contact tip; and an insulator coupled between the first and second conductive body portions.

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: 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: Submerged arc welding torches and systems to resistively preheat electrode wire are disclosed. A disclosed example submerged arc welding torch includes: a first contact tip configured to transfer weld current and preheating current to the wire; a second contact tip configured to conduct the preheating current to the wire; an air-cooled first conductive body portion configured to receive the weld current and to conduct the weld current and the preheating current to the first contact tip; an air-cooled second conductive body portion configured to receive the preheating current and to conduct the preheating current to the second contact tip; and an insulator coupled between the first and second conductive body portions.

Abstract: Systems and methods for inductance compensation in a welding-type system include a reel configured to wind a welding-type cable to reduce a first portion of the welding-type cable extending from the reel, and to unwind to increase the first portion of the welding-type cable extending from the reel, wherein a second portion of the welding-type cable is at least partially wound around the reel when stored. A controller determines a first length of the first portion of the welding-type cable, calculates a first inductance of the first portion of welding-type cable extending from the reel based on the first length, determines a second length of the second portion of the welding-type cable, calculates a second inductance of the second portion of welding-type cable wound around the reel based on the second length, and calculates a cable inductance of the welding-type cable based on the first inductance and the second inductance.

Abstract: 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; a cooling assembly configured to transfer heat from at least the first contact tip to coolant and to conduct the welding current through the cooling assembly; wherein the first contact tip and the cooling assembly are removable from the welding torch as a single unit.

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 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 and methods for setting the polarity of welding-type power provided by a welding-type power supply. The output polarity may be automatically selected based on one or more selectable welding parameters. The automatically selected polarity may be overridden based on operator input.

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: 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; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode via a second contact tip of the welding torch; and a preheat controller to: monitor a voltage drop across a second portion of the electrode; adjust at least one of the welding-type current or the preheating current based on the voltage drop, the second portion of the electrode comprising at least part of the first portion of the electrode; and control the preheating current based on a hydrogen reduction goal and based on stored parameters associated with a type of the electrode, a chemistry of the electrode, or a wire size.

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: 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 provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power 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 power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.

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.

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: Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power 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 power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.

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.