Abstract: Methods of arc welding and an arc welding assembly comprise a power source configured to provide a welding current, and a single weld housing. The weld housing comprises a welding torch, which comprises a consumable electrode wire. The welding torch defining an elongated member configured to utilize the welding current to melt at least part of the consumable electrode wire and provide welding current to the work piece. The weld housing further comprises a bypass torch defining an elongated member configured to divert a portion of the welding current away from the work piece while allowing other portions of the current to flow to the work piece.

Abstract: Welding systems and methods comprise a welding unit for joining a first and a second source of wire is provided. The welding unit of one embodiment comprises a wire feed tunnel defining a travel path through the welding unit for the first and second sources of wire. The welding unit further comprises a pair of wire feed ports disposed on opposite ends of the wire feed tunnel, and a wire joining zone disposed along a portion of the feed tunnel and configured to weld together an end of the first wire source to an end of the second wire source by applying weld heat to at least part of the respective ends of the first and second wire sources. The welding unit also comprises a switch configured to adjust the inner diameter of the wire feed tunnel until the inner diameter is substantially the same as the exterior diameter of the first and/or second sources of wire.