Abstract: Welding systems and methods include a welding unit for joining a first and a second source of wire, in which the welding unit includes a wire feed tunnel defining a travel path through the welding unit for the first and second sources of wire. The welding unit further includes 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 includes 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.

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: An apparatus and method for supplying a continuous source of wire includes a base supporting at least first and second sources of wire, a wire joining apparatus adjacent the base configured to weld a first wire from the first source with a second wire from the second source and a swing arm apparatus adjacent the first and second sources of wire. The swing arm apparatus may comprise a swing arm assembly configured to position a source cover over the second source of wire upon depletion of a feed wire in the first source of wire.

Abstract: An apparatus and method for supplying a continuous source of wire includes a base supporting at least first and second sources of wire, a wire joining apparatus adjacent the base configured to weld a first wire from the first source with a second wire from the second source and a swing arm apparatus adjacent the first and second sources of wire. The swing arm apparatus may comprise a swing arm assembly configured to position a source cover over the second source of wire upon depletion of a feed wire in the first source of wire.