Abstract: A contact tip for hot-wire welder is provided that are adapted to operate in deep and narrow recessed gaps within a work piece. Contact tips in accordance with the current invention provide for an assembly having a body portion with a cavity and an extension portion which is inserted into the cavity. The extension portion is non-electrically conductive and allows the contact tip assembly to reach into deep, narrow grooves without worry of shorting the contact tip of the consumable.

Abstract: A contact tip for hot-wire welder is provided that are adapted to operate in deep and narrow recessed gaps within a work piece. Contact tips in accordance with the current invention provide for an assembly having a body portion with a cavity and an extension portion which is inserted into the cavity. The extension portion is non-electrically conductive and allows the contact tip assembly to reach into deep, narrow grooves without worry of shorting the contact tip of the consumable.

Abstract: A method and system to start and/or stop a hot wire process. A hot wire system includes a filler wire feeder that includes a contact tube for holding a filler wire, a wire feed mechanism, a power supply for applying a heating current to the wire; and a controller coupled to the feed mechanism and the power supply. The controller is configured for regulating the heating current to the wire and locating the wire with respect to the workpiece for forming a molten puddle with an arc to initiate a hot wire process. The controller may also be configured to regulate the feed of the wire to the molten puddle and one of regulate and/or pulse the current to the wire so as to retract the wire out of the molten puddle in a stable manner when stopping the hot wire process.