Abstract: A welding system includes an electrode configured to be advanced toward a workpiece and a power supply configured to provide a flow of electricity to the electrode for generating a welding arc between the electrode and the workpiece. The welding system also includes a first sensor configured to sense a light intensity of the welding arc and a second sensor configured to sense a current provided to the electrode via the power supply. In addition, the welding system includes a controller communicatively coupled with the first and second sensors and configured to modify the light intensity with respect to the current. The controller is configured to control a welding parameter of the welding system based on the modified light intensity.

Abstract: A welding system includes a power supply configured to output power to a welding device. The power supply is configured to alternate the power output between an arc phase and a hotwire phase. The power output in the arc phase produces an arc between a welding electrode and a workpiece, and the power output in the hotwire phase heats the welding electrode without producing an arc.

Abstract: A constant voltage (CV) welding process power supply including a controller that implements a variable minimum current is provided. The controller is configured to periodically compute a running current value during a welding operation. The controller is also configured to periodically compute a minimum current value based on a difference between the running current value and a preset offset value, wherein the preset offset value remains constant throughout the welding operation.

Abstract: The present systems and methods relate generally to the field of welding systems, and particularly to flux-cored arc welding systems with self-shielded electrodes (FCAW-S). In an embodiment, a tubular welding wire includes a core and a sheath disposed around the core. Further, the tubular welding wire includes greater than approximately 2.4% glassy slag promoter by weight.

Abstract: A constant voltage (CV) welding process power supply including a controller that implements a variable minimum current is provided. The controller is configured to periodically compute a running current value during a welding operation. The controller is also configured to periodically compute a minimum current value based on a difference between the running current value and a preset offset value, wherein the preset offset value remains constant throughout the welding operation.

Abstract: A method for monitoring a spatter generating event during a welding application. The method includes capturing data that corresponds to a welding current of the welding application. The method also includes detecting parameters associated with a short circuit from the captured data. The method includes analyzing the detected parameters to monitor the spatter generating event during the welding application.

Abstract: A constant voltage (CV) welding process power supply is provided. The power supply includes a controller configured to detect a short circuit event in a CV welding process and increase a welding current based upon a periodically computed voltage error and a first gain to attempt to clear the short circuit event. The controller is further configured to detect whether the short circuit event has cleared after the first current increase. If the short circuit event has not cleared, the controller increases the welding current based upon the periodically computed voltage error and a second gain higher than the first gain.

Abstract: Stickout of a welding electrode wire from a welding torch is determined during welding, and based upon a welding parameter, such as welding current. Different relationships are used for the determination depending upon whether the welding wire is in a short-circuit condition or an arc condition. The stickout may be converted to a standardized unit of measure to make it readily understandable to an operator. The stickout may be logged and associated with other parameters and information, such as workpiece, operator, welding system, date and time. The stickout may be used as the basis for an alarm or a disabling operation. Moreover, the stickout may be provided on a readout for the operator. It may also be used as a basis for controlling a wire feeding apparatus that retracts the welding wire to a desired stickout following a weld.

Abstract: A welding system or an enterprise using welding systems can communicate with cloud-based resources for the provision of services and products to facilitate the welding operations. The communications may be via wired or wireless media, and may be direct, or through other components, such as enterprise networks, peripheral devices, and so forth. The cloud-based resources may provide for storage of data, particularly welding data, processing of data, welding protocols, specifications and processes, financial transactions for the purchase, licensing or use of welding-related products and services, welding training, and so forth.

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 constant voltage (CV) welding process power supply is provided. The power supply includes a controller configured to detect a short circuit event in a CV welding process and increase a welding current based upon a periodically computed voltage error and a first gain to attempt to clear the short circuit event. The controller is further configured to detect whether the short circuit event has cleared after the first current increase. If the short circuit event has not cleared, the controller increases the welding current based upon the periodically computed voltage error and a second gain higher than the first gain.

Abstract: A constant voltage (CV) welding process power supply including a controller that implements a variable minimum current is provided. The controller is configured to periodically compute a running current value during a welding operation. The controller is also configured to periodically compute a minimum current value based on a difference between the running current value and a preset offset value, wherein the preset offset value remains constant throughout the welding operation.