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: An example welding-type system 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 via a second contact tip of the welding torch; a switching circuit configured to control a current flow between the welding-type power source and the first contact tip; and a preheat control circuit configured to control the switching circuit to: selectively direct current from the welding-type power source to the second contact tip; and selectively divert current from the electrode preheating circuit to the first contact tip.

Abstract: Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

Abstract: Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

Abstract: Systems, methods, and apparatus to control weld current in a preheating system are disclosed. An example preheating power supply includes power conversion circuitry configured to output welding-type power via a first output power connector and a second output power connector, and a bypass path prevention circuit configured to prevent less than a threshold voltage applied to the first output power connector and the second output power connector from a different power supply from causing current to flow between the first output power connector and the second output power connector.

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: 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: 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: Systems, methods, and apparatus to control weld current in a preheating system are disclosed. An example preheating power supply includes power conversion circuitry configured to output welding-type power via a first output power connector and a second output power connector, and a bypass path prevention circuit configured to prevent less than a threshold voltage applied to the first output power connector and the second output power connector from a different power supply from causing current to flow between the first output power connector and the second output power connector.

Abstract: Systems, methods, and apparatus to control weld current in a preheating system are disclosed. An example preheating power supply includes power conversion circuitry configured to output welding-type power via a first output power connector and a second output power connector, and a bypass path prevention circuit configured to prevent less than a threshold voltage applied to the first output power connector and the second output power connector from a different power supply from causing current to flow between the first output power connector and the second output power connector.

Abstract: An example welding system includes: a welding power supply configured to convert input power to welding power; a wire feeder configured to feed welding wire to a welding torch; and control circuitry configured to: in response to an initiation of a welding process, control the wire feeder to feed the welding wire at a first rate while controlling the welding power supply to output the welding power to initiate a welding arc; in response to initiation of the welding arc, control the wire feeder to increase a feed rate of the wire feeder from the first rate to a second rate; and in response to determining that a temperature profile of a heated portion of the welding wire has stabilized, control the wire feeder to change the feed rate of the wire feeder from the second rate to a target wire feed speed.

Abstract: Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

Abstract: A method for monitoring a spatter generating event during a welding application. The method includes capturing data that corresponds to a welding current of the welding application. The method also includes detecting parameters associated with a short circuit from the captured data. The method includes analyzing the detected parameters to monitor the spatter generating event during the welding application.

Abstract: Systems and methods for cleaning a wire electrode after a welding process has ended are described. During a welding process, a wire electrode may be fed forward from a wire feeder through a welding torch to create a molten weld pool. While, conventionally, feeding of the wire electrode stops when the welding process ends, the present disclosure contemplates instead continuing to feed the wire electrode forward after the welding process ends. More particularly, the present disclosure contemplates feeding the wire electrode into the weld pool so that the wire electrode can be “cleaned” in the molten weld pool created by the welding process. The “cleaned” wire electrode end can be more easily used to establish an electrical arc at the beginning of the next welding process.

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 are described to address issues associated with welding with cored wires. In certain processes, a welding wire may “stick” or fuse to a contact tip, such as at termination of a weld. To mitigate the negative effects of a wire fusing to a contact tip, the wire remains in motion at a time prior to the end of the weld, as the weld ends, and/or for a time after the end of the weld, to limit and/or eliminate fusion between the wire and the contact tip.

Abstract: A welding regime may implements cyclic short circuits under a closed loop voltage control approach. Upon clearing or imminent clearing of the short circuit, a current recess is implemented. The current recess reduces the current that would otherwise be applied to the weld, resulting in multiple benefits. The recess may be implemented by suspending voltage command signals. Following the current recess, normal control is resumed with the then-current voltage command.

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.