Abstract: A method providing a welding apparatus configured to supply a welding wire to a welding gun and a welding system implementing the same is described. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program, the program dynamically adjusting the amount of welding wire retraction based at least upon one of the following: welding arc current, welding wire size, welding wire speed and burnback time. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire preferably does not extend (or minimally extends—or may be at least partially recessed within the tip) from the opening of the welding gun nozzle tip.

Abstract: The method of optimizing performance of a weld includes determining a set of specified mechanical properties, such as hardness or toughness for the weld, selecting a base metal material, selecting a welding process and welding process conditions, and selecting a weld metal material. The weld metal material and/or the base metal material may be selected by determining a characterization of the weld or base metal material, the characterization including performing a thermal-mechanical simulation of the metal materials and determining the properties of the metals produced by the thermal-mechanical simulation, and subsequently correlating the characterization of the metal materials with the set of specified mechanical properties and the welding process conditions. The method may also include producing said weld having said set of mechanical properties.

Abstract: The method of optimizing performance of a weld includes determining a set of specified mechanical properties, such as hardness or toughness for the weld, selecting a base metal material, selecting a welding process and welding process conditions, and selecting a weld metal material. The weld metal material and/or the base metal material may be selected by determining a characterization of the weld or base metal material, the characterization including performing a thermal-mechanical simulation of the metal materials and determining the properties of the metals produced by the thermal-mechanical simulation, and subsequently correlating the characterization of the metal materials with the set of specified mechanical properties and the welding process conditions. The method may also include producing said weld having said set of mechanical properties.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to at least one of a true energy and true power input to the welding output circuit path.

Abstract: A method providing a welding apparatus configured to supply a welding wire to a welding gun and a welding system implementing the same is described. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program, the program dynamically adjusting the amount of welding wire retraction based at least upon one of the following: welding arc current, welding wire size, and burnback time. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire either does not extend (or minimally extends) from the opening of the welding gun.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to a true energy and/or true power input to the welding output circuit path. A welding output circuit path is also characterized with respect to an inductance of the welding output circuit path. A welding output circuit path is further characterized with respect to a welding output waveform.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to at least one of a true energy and true power input to the welding output circuit path.

Abstract: Methods and apparatus to characterize a welding output circuit path. A welding output circuit path is characterized in real time with respect to a true energy and/or true power input to the welding output circuit path. A welding output circuit path is also characterized with respect to an inductance of the welding output circuit path. A welding output circuit path is further characterized with respect to a welding output waveform.