Abstract: Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.

Abstract: Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.

Abstract: A drive roll (180) adapted and configured to feed weld wire (54) comprises first and second opposing sides (238, 239) and an outer body surface (290). The outer body surface (290) comprises a base body surface (BBS), and at least one elevated wire interface (244) extending outwardly from and along at least a major portion of the base body surface. The elevated wire interface (244) can rotationally drivingly engage the weld wire (54), which enables the drive roll (180) to advance the weld wire (54) along e.g. a desired path of travel such as to a welding arc.

Abstract: A welding gun power pin for attaching a welding gun to a power block of a welding system. The welding gun power pin includes a generally cylindrical pin body, and insertion stop member, and a withdrawal stop member which defines a withdrawal stop member length dimension. A channel extends into the outer circumferential surface of the pin body, generally separates the pin body from the withdrawal stop member, and is adapted and configured to accept a generally rigid projection member therein, whereby to mechanically resist withdrawal of the welding gun power pin from the remainder of the welding system. The channel defines a channel width dimension which has a magnitude that is less than the magnitude of the withdrawal stop member length dimension.

Abstract: A wire pinch force mechanism has a drive assembly which includes at least a first drive roll and a second drive roll adapted and configured to drive a weld wire. The pinch force mechanism further includes a cover movable between a first relatively open position and a second relatively closed position; and a force converter, mounted to the cover, which communicates with and applies an adjustable force to the drive assembly.

Abstract: A wire guide (16), for a drive assembly (56) of a wire feeding assembly (16), of a welding system (10), has an elongate body with an outer surface, a length, and first (296A) and second (296B) ends. An elongate bore (255) extends along the length of, and through, the elongate body. An aperture (265) extends through the elongate body, generally transverse to, and intersecting, the elongate bore (255). In preferred embodiments, at least one generally arcuate depression (260, 262) extends into the outer surface of the elongate body, communicating with the aperture (265) which extends through the elongate body, in a direction transverse to the elongate bore (255).

Abstract: A power block for holding a welding gun power pin has receiving structure which defines a bore which receives and holds a welding gun power pin. The power block further includes a projection movable between at least a first position and a second position. When the projection is in the first position, the projection extends at least partially into the receiving structure cavity. When the projection is in the second position, the projection generally does not extend into the receiving structure cavity. In some embodiments, the projection has a generally straight line distal edge. In other embodiments, the projection has a generally arcuate distal edge.

Abstract: A drive roll release mechanism is rotatable about an axis of rotation and includes a drive roll carrier body having a carrier body sidewall adapted and configured to accept a drive roll thereon. The drive roll release mechanism further includes an actuator in sliding communication with the carrier body. A user depresses the actuator to correspondingly realize at least a partial release of a drive roll, which is removably mounted to the drive roll release mechanism, from the carrier body, enabling facile removal of the drive roll from the drive roll release mechanism.

Abstract: A welding gun inlet for use with a welding gun power pin of a welding gun. The welding gun inlet includes an inlet body which has a first end and a second end and a tapered outer wall which generally tapers downwardly from a relatively larger diameter portion adjacent the first end to a relatively lesser diameter portion adjacent the second end. The welding gun inlet further includes an insertable member which extends outwardly from the inlet body. The insertable member has a length and defines a relatively constant cross-sectional diameter along at least a major portion of the length of the insertable member.

Abstract: A wire guide, for a drive assembly of a wire feeding assembly, of a welding system, has an elongate body which has with an outer surface, a length, and first and second ends. An elongate bore extends along the length of, and through, the elongate body. An aperture extends through the elongate body, generally transverse to, and intersecting, the elongate bore. In some embodiments, the elongate body includes first and second body portions which can axially, laterally, and/or rotationally move with respect to each other. A generally arcuate recess can extend transversely into the outer surface of the elongate body, and can communicate with the aperture which extends through the elongate body, in a direction transverse to the elongate bore.