Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: Embodiments of systems and methods in pulsed arc welding. A robotic welding system, having a welding torch with a contact tip, is configured to perform the following method: (a) generate and output a series of a determined number of welding output pulses as a welding wire electrode is fed toward a workpiece; (b) stop generating welding output pulses while allowing the welding wire electrode to continue to be fed toward the workpiece in an attempt to electrically short to the workpiece; (c) attempt to confirm that the welding wire electrode has electrically shorted to the workpiece within a determined error time period; and (d) repeat steps (a) through (c) if electrical shorting of the welding wire electrode has been confirmed within the determined error time period, else, shut down the robotic welding system to avoid damaging the welding torch.

Abstract: Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: A welding system includes a consumable electrode, torch, wire feeder, and power supply. The power supply is configured to provide a plurality of waveforms to the torch to generate a welding current in the electrode. Each of the plurality of waveforms includes a pinch current portion followed by an arcing current portion, and the pinch current portion is preceded by a first arc suppression portion and the arcing current portion is followed by a second arc suppression portion. An arc exists between the electrode and a workpiece during the arcing current portion, and an air gap without an arc exists between the consumable electrode and the workpiece during the arc suppression portions. The power supply is configured to detect a short between the electrode and workpiece and generate the pinch current portion when the short is detected, and the wire feeder stops feeding the electrode when the short is detected and restarts feeding the electrode after the short is clear.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.

Abstract: A shielded metal arc welding system includes a stick electrode holder, a stick electrode clamped by the holder, and a welding power supply operatively connected to the holder and configured to supply a welding current to the electrode through the holder. The power supply includes a memory storing both of a short circuit threshold voltage level and an arcing threshold voltage level. A welding voltage level is detected during an initial shorting of the electrode to a workpiece for commencing a welding operation. Both of the short circuit threshold voltage level and the arcing threshold voltage level are adjusted based on the detected welding voltage level. A short circuit clearing routine is activated when the welding voltage level is equal to or less than the adjusted short circuit threshold voltage level, and deactivated when the welding voltage level is equal to or greater than the adjusted arcing threshold voltage level.

Abstract: A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Abstract: Embodiments of welding systems and methods for reducing spatter in pulsed welding are disclosed. A welding power source includes a first welding output stud to be electrically connected to a consumable welding electrode and a second welding output stud to be electrically connected to a workpiece. Power electronics generate welding output current pulses. A switching network is connected between the power electronics and the first welding output stud. A controller is connected between the power electronics and the switching network. The controller controls the timing of each welding output current pulse and switches the switching network back and forth between a first welding output current flowing state and a second welding output current impeding state based on the timing. An increase in a decay rate of a trailing edge of each welding output current pulse is effected during the second welding output current impeding state.

Abstract: A welding or additive manufacturing power supply includes a user interface that receives a user input shielding gas mixture comprising separately adjustable amounts of a first and a second shielding gas. Output circuitry generates a shielding gas customized welding waveform. A memory stores a first plurality of waveform parameters that are associated with the first shielding gas, and a second plurality of waveform parameters that are associated with the second shielding gas. A controller is operatively connected to control operations of the output circuitry, and is configured to determine a third plurality of waveform parameters at least partially defining the shielding gas customized welding waveform. The controller determines the third plurality of waveform parameters from the first and second plurality of waveform parameters and the amounts of the first and second shielding gas.

Abstract: A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

Abstract: A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

Abstract: Embodiments of systems and methods related to pulsed arc welding are disclosed. A robotic welding system, having a welding torch with a contact tip, is configured to perform the following method: (a) generate and output a series of a determined number of welding output pulses as a welding wire electrode is fed toward a workpiece; (b) stop generating welding output pulses while allowing the welding wire electrode to continue to be fed toward the workpiece in an attempt to electrically short to the workpiece; (c) attempt to confirm that the welding wire electrode has electrically shorted to the workpiece within a determined error time period; and (d) repeat steps (a) through (c) if electrical shorting of the welding wire electrode has been confirmed within the determined error time period, else, shut down the robotic welding system to avoid damaging the welding torch.

Abstract: A welding system includes a power supply configured to output a series of welding waveforms for generating a welding current in a consumable welding electrode, and a wire feeder that advances the electrode toward a weld puddle during a welding operation. The wire feeder includes a subcircuit having a switching device and parallel resistance, the subcircuit being connected in series with the electrode such that the welding current flows through the subcircuit. The switching device is controllable between conducting and nonconducting states. The wire feeder includes a controller operatively connected to the switching device that controls switching operations of the switching device. The power supply is configured to remotely identify occurrences of the switching operations in the wire feeder and control the welding waveforms based on the occurrences of the switching operations.

Abstract: A welding system comprises a welding power source that provides an alternating current in a selected wave form having a set of positive and negative portions, the negative portion consisting of a peak, tailout, and background phase, and the positive portion consisting of a peak, tailout, and background; wherein the power source provides an upward ramping current during the pinch and detachment phase, switches to an electrode negative current during the negative peak, tailout, and background phases, and switches to a subsequent electrode positive portion; wherein, the positive portion may repeat prior to the next shorting event.

Abstract: A welding system includes a consumable welding electrode, a feeder that advances the consumable welding electrode toward a weld puddle during a welding operation, and a power supply configured to provide a series of welding waveforms to the consumable welding electrode to generate a welding current in the consumable welding electrode. An individual welding waveform of said series includes a predetermined minimum current portion, a peak current portion, and a background current portion having a magnitude that is greater than the minimum current portion and less than the peak current portion. The power supply comprises an adjustable resistance for setting a magnitude of the minimum current portion. The adjustable resistance is connected in series with the consumable welding electrode such that the minimum current portion of the welding current flows through the adjustable resistance.

Abstract: A welding system comprises a welding power source that provides an alternating current in a selected wave form having a set of positive and negative portions, the negative portion consisting of a peak, tailout, and background phase, and the positive portion consisting of a peak, tailout, and background; wherein the power source provides an upward ramping current during the pinch and detachment phase, switches to an electrode negative current during the negative peak, tailout, and background phases, and switches to a subsequent electrode positive portion; wherein, the positive portion may repeat prior to the next shorting event.