Abstract: A system and method to correct for height error during a robotic additive manufacturing process. One or both of an output current, output voltage, output power, output circuit impedance and a wire feed speed are sampled during an additive manufacturing process when creating a current layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the output current, output voltage, output power, output circuit impedance and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current layer.

Abstract: Methods and system of the present invention include hot-wire strip deposition system used in combination with a high heat source, where the system deposits a strip consumable into a molten puddle. During deposition the strip consumable is deposited at an angle relative to the workpiece surface and in some embodiments has a downforce applied to the consumable to maintain contact between the puddle and the consumable. The heating current for the consumable is turned off or greatly reduced when an arcing event is detected. In some embodiments the strip consumable can be curved to promote contact during the deposition process.

Abstract: A method and system to manufacture workpieces employing a high intensity energy source that irradiates a surface of a workpiece to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets. Preferably, a wire feeding device feeds the wire to the puddle, and a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire which is deposited into the puddle.

Abstract: A system and method to correct for height error during a robotic additive manufacturing process. One or both of an output current, output voltage, output power, output circuit impedance and a wire feed speed are sampled during an additive manufacturing process when creating a current layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the output current, output voltage, output power, output circuit impedance and the wire feed speed. An average CTWD is determined based on the plurality of instantaneous CTWD's. A correction factor is generated, based on at least the average CTWD, which is used to compensate for any error in height of the current layer.

Abstract: A hermetically sealed wheel assembly which has been welding autogenously is provided, along with a method and system for welding the wheel assembly. The wheel assembly is made up of at least two components which are laser welded to each other without the use of filler material to create a hermetically sealed wheel assembly.

Abstract: A system and method is provided where a coated work piece is welded at high speeds with minimal porosity and spatter. The coating on the work piece is removed or ablated by a high energy heat source prior to being welded in a welding operation, such that high welding speeds are attained. The high energy heat source is positioned upstream of the welding operation to vaporize any surface coatings on a work piece.

Abstract: A filler wire (consumable) for depositing self-lubricating materials in a system for any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications. The filler wire is composed of a base filler material consistent with commonly known compositions. For example, the base filler material can comprise standard materials used in many standard mild steel wires. In addition to the base filler materials, the consumable includes self-lubricating materials. The self-lubricating materials include at least one of graphite particles and graphite powder, and can include other self-lubricating materials.

Abstract: A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

Abstract: A system and method is provided where a coated work piece is welded at high speeds with minimal porosity and spatter. The coating on the work piece is removed or ablated by a high energy heat source prior to being welded in a welding operation, such that high welding speeds are attained. The high energy heat source is positioned upstream of the welding operation to vaporize any surface coatings on a work piece.

Abstract: A system and method is provided where a coated work piece is welded at high speeds with minimal porosity and spatter. The coating on the work piece is removed or ablated by a high energy heat source prior to being welded in a welding operation, such that high welding speeds are attained. The high energy heat source is positioned upstream of the welding operation to vaporize any surface coatings on a work piece.

Abstract: A filler wire (consumable) for depositing self-lubricating materials in a system for any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications. The filler wire is composed of a base filler material consistent with commonly known compositions. For example, the base filler material can comprise standard materials used in many standard mild steel wires. In addition to the base filler materials, the consumable includes self-lubricating materials. The self-lubricating materials include at least one of graphite particles and graphite powder, and can include other self-lubricating materials.

Abstract: A filler wire (consumable) for depositing wear-resistant materials in a system for any of brazing, cladding, building up, filling, hard-facing overlaying, welding, and joining applications is provided. The consumable is composed of base filler materials consistent with commonly known compositions. For example, the base filler material can comprise standard materials used in many standard mild steel wires. In addition to the base filler materials, the consumable includes wear-resistant materials. The wear-resistant materials include at least one of amorphous metallic powder, diamond crystals, diamond powder, tungsten carbide, and aluminides.

Abstract: A hermetically sealed wheel assembly which has been welding autogenously is provided, along with a method and system for welding the wheel assembly. The wheel assembly is made up of at least two components which are laser welded to each other without the use of filler material to create a hermetically sealed wheel assembly.

Abstract: A system and method is provided where a coated work piece is welded at high speeds with minimal porosity and spatter. The coating on the work piece is removed or ablated by a high energy heat source prior to being welded in a welding operation, such that high welding speeds are attained. The high energy heat source is positioned upstream of the welding operation to vaporize any surface coatings on a work piece.

Abstract: To overcome 1) the high levels of porosity due to coating material vaporization and entrapment into the weld, 2) spewing of molten base metal from the weld leaving holes and pits in the weld, and 3) humping effects when oblong beam configurations are used at higher weld speeds to weld coated materials, the present invention features an energy source (10) with multiple separated energy beams (24, 26) (formed by using multiple separate beam sources or manipulation of a single beam (14) into separated multiple energy beams (44, 46) using wedge mirror (18) and parabolic focusing mirror (20)) that produces high quality (porosity free) lap welds in a weld stack (50) of layered materials (30, 32) coated with coating material (28, 28′, 34, 34′) with zero gap at interface (38) during the welding process.