Abstract: Welding wires may include a high alloy metal core comprising greater than about 10.5 percent by weight of the high alloy metal core of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy. Welding methods may include applying an electrical current sufficient to convert a welding wire to a molten state to produce a molten weld material, the welding wire comprising: a high alloy metal core comprising greater than about 10.5% of a component selected from aluminum, bismuth, chromium, molybdenum, chromium/molybdenum alloy, cobalt, copper, manganese, nickel, silicon, titanium, tungsten, vanadium, or a combination thereof; and a layer surrounding the high alloy metal core, the layer comprising copper or a copper alloy; and depositing the molten welding material onto a workpiece.

Abstract: The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

Abstract: The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

Abstract: The disclosed technology generally relates to welding, and more particularly to a consumable welding wire for metal arc welding, and a method and a system for metal arc welding using the consumable welding wire. In one aspect, a method of arc welding includes providing a welding wire comprising one or more alkaline earth metal elements. The method additionally includes applying power to the welding wire to generate a plasma arc sufficient to melt the welding wire. The method further includes depositing molten droplets formed by melting the welding wire onto a workpiece at a high deposition rate while regulating to maintain a substantially constant power delivered to the plasma arc.

Abstract: An arc welder produces a weave pattern between workpieces. Each weld run comprises a center portion including a joining region between the workpieces and edge regions spaced apart from the joining region. The welder includes a power source that provides a welding waveform to a welding electrode to generate an arc to achieve a desired heat for welding, a welding torch, and an oscillator for oscillating the torch between the welding edge regions. A controller causes the power source to operate in a first mode utilizing a first waveform during welding within the joining region, and in a second mode using a second waveform, having a greater positive component than the first waveform, during welding within the edge regions. The controller determines a stickout value based on the first waveform but not the second waveform, and performs seam tracking based the second waveform but not the first waveform.

Abstract: The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

Abstract: The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

Abstract: An arc welder produces a weave pattern between workpieces. Each weld run comprises a center portion including a joining region between the workpieces and edge regions spaced apart from the joining region. The welder includes a power source that provides a welding waveform to a welding electrode to generate an arc to achieve a desired heat for welding, a welding torch, and an oscillator for oscillating the torch between the welding edge regions. A controller causes the power source to operate in a first mode utilizing a first waveform during welding within the joining region, and in a second mode using a second waveform, having a greater positive component than the first waveform, during welding within the edge regions. The controller determines a stickout value based on the first waveform but not the second waveform, and performs seam tracking based the second waveform but not the first waveform.

Abstract: The disclosed technology generally relates to welding, and more particularly to a consumable welding wire for metal arc welding, and a method and a system for metal arc welding using the consumable welding wire. In one aspect, a method of arc welding includes providing a welding wire comprising one or more alkaline earth metal elements. The method additionally includes applying power to the welding wire to generate a plasma arc sufficient to melt the welding wire. The method further includes depositing molten droplets formed by melting the welding wire onto a workpiece at a high deposition rate while regulating to maintain a substantially constant power delivered to the plasma arc.