Abstract: A welding system and method provide for generating a controlled waveform for welding power output, the waveform comprising a plurality of successive peak phases designed to avoid or reduce micro-arcing when used with metal-cored or flux-cored electrode wires. Ratios of the background current and voltage levels are elevated as compared to conventional techniques, with the levels in most cases exceeding 50% of the peak currents and voltages. Transitions between background and peak levels of current and voltage are also smoothed, and the duration of the peak phase as compared to the duration of each pulse cycle is elongated to further reduce micro-arcing.

Abstract: A method and device for controlling current flow through a welding clamp are provided. One welding clamp includes a first contact piece configured to contact a workpiece and to provide a first current path that limits current flow. The welding clamp also includes a second contact piece configured to contact the workpiece and to provide a second current path. When the welding clamp is being clamped to the workpiece, the first contact piece is configured to contact the workpiece prior to the second contact piece. In addition, the welding clamp is configured so that current flows through the first current path prior to flowing through the second current path when the welding clamp is being clamped to the workpiece.

Abstract: A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Abstract: A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Abstract: A welding system and method provide for generating a controlled waveform for welding power output, the waveform comprising a plurality of successive peak phases designed to avoid or reduce micro-arcing when used with metal-cored or flux-cored electrode wires. Ratios of the background current and voltage levels are elevated as compared to conventional techniques, with the levels in most cases exceeding 50% of the peak currents and voltages. Transitions between background and peak levels of current and voltage are also smoothed, and the duration of the peak phase as compared to the duration of each pulse cycle is elongated to further reduce micro-arcing.

Abstract: A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Abstract: A system and method for stabilizing a welding arc is disclosed. The method of initiating the arc includes the steps of defining a wire feed speed based on a user selected wire feed speed and then abruptly reducing the wire feed speed before the wire feed speed reaches a relatively stabilized speed for welding, thereby allowing a welding arc to initiate and propagate to a generally steady state.

Abstract: A method and system to determine optimum operating parameters for the startup phase of a welding-type process based on user-desired operating parameters of the post-startup or welding phase of the welding-type process are disclosed. While applicable to a number of welding-type processes, the method and system are particularly configured to determine an optimum wire feed speed for Gas Metal Arc Welding of aluminum using pulse spray transfer.

Abstract: A method and device for controlling current flow through a welding clamp are provided. One welding clamp includes a first contact piece configured to contact a workpiece and to provide a first current path that limits current flow. The welding clamp also includes a second contact piece configured to contact the workpiece and to provide a second current path. When the welding clamp is being clamped to the workpiece, the first contact piece is configured to contact the workpiece prior to the second contact piece. In addition, the welding clamp is configured so that current flows through the first current path prior to flowing through the second current path when the welding clamp is being clamped to the workpiece.

Abstract: An external support structure for a welding power supply includes a cage-like assembly that is configured to receive and at least partially surround the welding power supply. The cage-like assembly includes fastening points allowing for securement of the welding power supply within the assembly. The assembly further includes stacking members to permit stacking of the assembly with a self-similar structure.

Abstract: Embodiments of a welding system include a compact wire feeder adapted to feed welding wire having a diameter up to approximately 5/64 inches disposed on a wire spool having an outer diameter of approximately 8 inches. The compact wire feeder may include a housing, a spool mounting hub disposed in the housing and adapted to receive the wire spool, and a wire drive assembly having a motor adapted to apply an output torque to a shaft of a gearbox to drive the welding wire from the welding spool to a welding torch.

Abstract: A system and method for stabilizing a welding arc is disclosed. The method of initiating the arc includes the steps of defining a wire feed speed based on a user selected wire feed speed and then abruptly reducing the wire feed speed before the wire feed speed reaches a relatively stabilized speed for welding, thereby allowing a welding arc to initiate and propagate to a generally steady state.

Abstract: A system and method for stabilizing a welding arc is disclosed. The method of initiating the arc includes the steps of defining a wire feed speed based on a user selected wire feed speed and then abruptly reducing the wire feed speed before the wire feed speed reaches a relatively stabilized speed for welding, thereby allowing a welding arc to initiate and propagate to a generally steady state.