Abstract: Flux cored welding electrodes comprise a iron based metal sheath and either a flux or metal core within the sheath, enclosing core ingredients. The core ingredients and sheath together comprise, in weight percentages based on the total weight of the electrode, very low levels of manganese. While having low levels of manganese the electrodes satisfy the strength and safety requirements required of commercial electrodes. Embodiments contain manganese in the range of 0.09 to 0.19% by weight of the electrode, along with other components.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: Embodiments of flux cored welding electrodes and methods of use thereof are disclosed. The flux cored welding electrodes limit brittleness of flux cored arc welds, particularly in thick weld deposits. Limiting brittleness in thick (e.g., from about 1? to about 6?) flux cored arc welds is achieved by utilizing flux cored welding electrodes having chemical compositions that reduce (as compared to presently marketed electrodes) or altogether eliminate niobium and vanadium from their chemical compositions.

Abstract: Embodiments of the invention relate to consumables that are used with non-arc deposition processes, including hot-wire deposition processes. Exemplary embodiments of the present invention eliminate the use of arc initiators or arc stabilizers in the consumable. Other embodiments add additional amounts of carbonates in the consumable than would otherwise be present in consumables for arc welding processes. Similarly, other exemplary embodiments of the present invention include additional amounts of nitrides than would otherwise be present in arc process consumables. Other exemplary embodiments include carbides that are desired to be deposited through the non-arc processes.

Abstract: A system and method for using gas flow to control a molten puddle in out-of-position applications is provided. The system includes a high intensity energy source configured to heat at lease one workpiece to create a molten puddle and a housing assembly configured to supply a gas over the molten puddle in order to minimize sagging of the molten puddle in the out-of-position applications. The system also includes a gas source that is configured to supply the gas. The gas source is operatively connected to the housing assembly. The pressure of the gas in the housing assembly is in a range of 15 psi to 35 psi. The method includes heating at least one workpiece to create a molten puddle and supplying a gas over the molten puddle via a housing assembly in order to minimize sagging of the molten puddle in the out-of-position applications.

Abstract: A system and method for using filler wire in hot wire applications, e.g., brazing, cladding, building up, filling, overlaying, welding, and joining applications, is provided. The filler wire has a first section that has a first resistance per unit length. The filler wire has a second section that has a second resistance per unit length, which is higher than the first resistance per unit length. The second section of the filler wire is configured to melt before the first section during hot-wire applications. In some embodiments, a resistivity of the first section and a resistivity of the second section are equal and the second section has a cross-sectional area that is smaller than a cross-sectional area of the first section. In some embodiments, a resistivity of filler material in the first section and a resistivity of filler material in the second section are different.

Abstract: A system and method for removing material in a workpiece is provided. The system includes a laser system that melts a portion of the workpiece by heating the workpiece. The system includes a wire feeder system that feeds a wire to the workpiece to remove molten metal from the workpiece by using the wire. The wire is configured such that the molten metal adheres to the wire when the wire makes contact with the molten metal. The melting by the laser system includes a cutting or a gouging of the workpiece. In some embodiments, the system includes a hot wire power supply that supplies heating current through a length of the wire to heat the length of the wire to a desired temperature. The heating of the wire facilitates the adherence of the molten metal to the wire.

Abstract: A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: A flux for use in arc welding of a stainless steel workpiece with a consumable metal electrode having a precentage of chromium, which welding flux comprises a silica containing system for forming a slag on the surface of the deposited chromium-bearing alloy weld metal and a bismuth containing slag releasing agent selected from the class consisting of elemental bismuth, bismuth fluoride, bismuth sulfide, bismuth titanate, bismuth oxy carbonate, bismuth oxy-chloride and mixtures thereof. Also, there is provided an electrode employing this flux.