Abstract: An arc welding system providing improved molten metal droplet transfer. The system includes a welding power source having a welding power supply, a welding waveform generator, and a controller. Two fluxed cored welding wire electrodes are connected to the power source and are powered by the same welding output voltage and current produced by the power source. A feedback circuit is connected to the power source to provide an adaptive response to maintain an average welding output voltage. The controller controls the waveform generator and the power supply to superimpose welding current pulses onto a welding waveform of a CV flux cored arc welding process, that uses CO2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process. The current pulses are superimposed in time to form molten metal droplets between ends of the two electrodes during the modified welding process.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A welding or additive manufacturing wire drive system includes a spindle. First and second welding wire spools are mounted on the spindle. The spools include a flange, a mounting hub, a barrel, and a wire electrode wound on the barrel. At least two drive rolls simultaneously draw first and second wire electrodes from the spools. A clutch disk is mounted on the spindle and has respective frictional surfaces in contact with one or both of the flange and mounting hub on the spools to frictionally engage the spools. The clutch disk allows the spools to slip relative to each other during an operation of the at least two drive rolls such that the spools rotate at different speeds while the wire electrodes are drawn from the spools.

Abstract: An arc welding system providing improved molten metal droplet transfer. The system includes a welding power source having a welding power supply, a welding waveform generator, and a controller. Two fluxed cored welding wire electrodes are connected to the power source and are powered by the same welding output voltage and current produced by the power source. A feedback circuit is connected to the power source to provide an adaptive response to maintain an average welding output voltage. The controller controls the waveform generator and the power supply to superimpose welding current pulses onto a welding waveform of a CV flux cored arc welding process, that uses CO2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process. The current pulses are superimposed in time to form molten metal droplets between ends of the two electrodes during the modified welding process.

Abstract: A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing system includes a power supply having a controller which controls operation of the power supply. The power supply provides a current waveform to a contact tip assembly having a first bore terminating at a first exit orifice and a second bore terminating at a second exit orifice. The first exit orifice is configured to deliver a first wire electrode and said second exit orifice is configured to deliver a second wire electrode. The exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between the wire electrodes while preventing solid portions of the first wire electrode delivered through the first bore from contacting solid portions of the second wire electrode delivered through the second bore, during a deposition operation in which the current waveform is conducted to both of the wire electrodes simultaneously through the contact tip assembly.

Abstract: A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.

Abstract: A gas tungsten arc welding torch includes a handle and a nozzle located distal of the handle and having a central bore. First and second tungsten electrodes are located partially within the central bore of the nozzle. The torch includes at least one filler wire channel that terminates radially inward of the first tungsten electrode and the second tungsten electrode. The torch includes a torch trigger. Operation of the torch trigger controls delivery of a first filler wire and a second filler wire through the at least one filler wire channel. The torch includes a wire feed speed control. Operation of the wire feed speed control adjusts a wire feed speed of both of the first filler wire and the second filler wire.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll having a first annular groove, a second drive roll having a second annular groove, a first welding wire located between the drive rolls in the annular grooves, and a second welding wire located between the drive rolls in the annular grooves. A biasing member biases the first drive roll toward the second drive roll to force the first welding wire to contact the second welding wire. The first welding wire contacts each of a first sidewall portion of the first annular groove, a first sidewall portion of the second annular groove, and the second welding wire. The second welding wire contacts each of a second sidewall portion of the first annular groove, a second sidewall portion of the second annular groove, and the first welding wire. The drive rolls rotate in opposite directions thereby moving the welding wires through the wire drive system.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

Abstract: A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

Abstract: A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Abstract: A welding or additive manufacturing system includes a power supply having a controller which controls operation of the power supply. The power supply provides a current waveform to a contact tip assembly having a first bore terminating at a first exit orifice and a second bore terminating at a second exit orifice. The first exit orifice is configured to deliver a first wire electrode and said second exit orifice is configured to deliver a second wire electrode. The exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between the wire electrodes while preventing solid portions of the first wire electrode delivered through the first bore from contacting solid portions of the second wire electrode delivered through the second bore, during a deposition operation in which the current waveform is conducted to both of the wire electrodes simultaneously through the contact tip assembly.

Abstract: A welding or additive manufacturing wire drive system includes a first spindle for a first welding wire spool, a second spindle for a second welding wire spool, a first drive roll, and a second drive roll. One or both of the drive rolls has a circumferential groove. A first welding wire and a second welding wire are located between the first drive roll and the second drive roll in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove. The second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.