Abstract: A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other.

Abstract: An extruded filler wire for use in a hot wire process. The filler wire includes a first core component; and a second coating component coupled to at least a portion of the first core component, the second coating component having a different composition from the first component, where the wire has a cross-sectional area with the first and second components asymmetrically arranged about a center of the wire.

Abstract: A method and system with a welding torch having a contact tip which has an upper portion and a lower portion, where the upper portion and the lower portion are electrically isolated from each other and each of the upper portion and the lower portion make contact with the same electrode during a welding operation. A first power supply is coupled to the upper portion which provides a first current to the upper portion during the welding operation, and a second power supply is coupled to the second portion which provides a second current during the welding operation. The first and second currents are accumulated in the electrode during welding to provide a welding waveform. The first power supply can have a higher inductance than the second power supply.

Abstract: A system and method is provided in which a welding system modulates the heat input into a weld joint during welding by changing between a high heat input welding waveform and a low heat input welding waveform. The system can utilize detected weld joint geometry and thickness to vary the utilization of the high heat and low heat waveform portions to change the weld bead profile during welding. Additionally, the wire feed speed is changed with the changes between the high heat input and low heat input portions of the welding waveform.

Abstract: A system and method is provided which uses a power supply which receives an input signal and provides an output signal to an electrode, where the output signal generates an arc between the electrode and at least one workpiece, and the output signal has a desired output power profile. The power supply has at least an output power circuit which determines an output power of the output signal, a power differential calculator which determines a difference between the determined output power and the desired output power profile, and a waveform generator which changes a power output of the output signal based on the determined difference between the desired output power profile and the determined output power.

Abstract: A method for root pass welding steel plate and pipe is provided that uses pulse arc welding having a current pulse waveform exhibiting a low constant background current and fixed frequency. The welding process may be performed without a backer or backing material.

Abstract: A method and system to weld or join workpieces of different materials employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

Abstract: An improvement in a welder including a power source for performing a TIG welding process across an electrode and a workpiece where the power source has a first output lead connected to the electrode and a second output lead connected to the workpiece with a controller for creating a waveform across the power leads. The waveform has a profile alternating between a first current section and a second current section at a given overall frequency and the sections each have a peak current in either the positive or negative direction and a duration. The improvement comprises at least one of the current sections being pulsed between a high current level equal to its peak current and a low current level in the opposite direction of the peak current at a pulsing frequency greater than the given overall frequency.

Abstract: A system and method of welding is provided where a pulse welding power supply is coupled with a magnetic field power supply such that a magnetic field can be generated proximate to a welding arc during pulse welding. During pulse welding a magnetic field is used to direct the welding arc and a droplet being transferred in the arc.

Abstract: A system and method is provided in which each of a GMAW power supply and a TIG/plasma power supply are utilized in a common weld joint, where the waveforms from each of the power supplies are pulsed waveform which are pulsed out of phase which each other. Such a system minimizes arc interference and arc blow while at the same time increasing travel speed and throughput of a welding operation.

Abstract: Welding systems and programming tools are described, in which a touch screen-based welding system configuration tool is provided having a touch screen display for designing welding power source waveforms or for configuring a system sequence controller, where the touch screen may be integrated into a welding system component. The touch screen displays information related to a switching type welding power source and/or a welding system sequence controller, as well as one or more touch activation indicia to allow a user to numerically or graphically configure the power source or the sequence controller by touching the touch activation indicia.

Abstract: An electric arc welder for producing a weave pattern across a workpiece with a succession of individual weld short runs or bead, each of which has a center portion extending between two transversely spaced edges. The welder comprising a power source, a wire feeder to direct a welding wire through a movable torch to the workpiece and a controller for creating a welding current between the wire and the workpiece. A mechanical device is used to move the torch along the bead and the controller has a program to perform a first weld process while the torch is moving along the center portion and a second weld process when the torch is adjacent the edges, where the first weld process has less heat input than the second weld process.

Abstract: A system and method is provided in which a surface tension transfer welding function is employed where the welding waveform switches polarity during welding when a short circuit event is detected.

Abstract: A system and method is provided where a work piece is welded at high speeds with minimal porosity and spatter. In embodiments, the work piece is welded with an arc welding process to create a weld puddle and the weld puddle is irradiated by a energy beam downstream of the arc welding operation, such that high welding speeds are attained. The high energy heat source is positioned downstream of the welding operation to input energy into the weld puddle to change its shape or characteristics to optimize bead shape and/or bead quality.

Abstract: A welding device includes an electrode head adapted to concurrently house an array of associated multiple, continuous-feed electrodes in a spaced apart configuration for concurrently depositing cladding material on the surface of a workpiece. The electrode head may be actuatable through a welding trajectory. The welding device may also include a welding power source adapted to provide power for simultaneously establishing a welding arc between each of the multiple, continuous-feed electrodes and the workpiece.

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

Abstract: A method and a system to increase heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. A cycle of the electric welding waveform includes a pinch current phase providing an increasing pinch current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and a background current phase providing a background current level. At least one heat-increasing current pulse of the cycle is generated, providing a heat-increasing current level, during the background current phase, where the heat-increasing current level is above the background current level. The cycle of the electric welding waveform with the at least one heat-increasing current pulse may be repeated until the arc welding process is completed.

Abstract: A method and system to start and/or stop a hot wire process. A hot wire system includes a filler wire feeder that includes a contact tube for holding a filler wire, a wire feed mechanism, a power supply for applying a heating current to the wire; and a controller coupled to the feed mechanism and the power supply. The controller is configured for regulating the heating current to the wire and locating the wire with respect to the workpiece for forming a molten puddle with an arc to initiate a hot wire process. The controller may also be configured to regulate the feed of the wire to the molten puddle and one of regulate and/or pulse the current to the wire so as to retract the wire out of the molten puddle in a stable manner when stopping the hot wire process.

Abstract: A method and a system to control heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. The welding waveform has droplet transfer pulses and at least one heat input pulse which is generated during a background portion of the waveform. The at least one heat-increasing current pulse is above the background current level and has a polarity opposite of that of the droplet transfer pulse.

Abstract: A welding system and method is provided for welding heavy plate, where the method and device include using a laser which directs a beam to a first weld puddle to weld at least a portion of a work piece and a welding torch to direct a first welding electrode to the first weld puddle while the beam is being directed to the weld puddle. The welding torch deposits the first welding electrode to create a first weld bead. A flux nozzle is employed to deposit a welding flux onto the weld bead, and a submerged arc welding torch is used to direct a submerged arc filler metal to the weld bead to create a second weld bead through a submerged arc welding process, where the submerged arc welding process melts a portion of the first weld bead to consume the melted portion into the second weld bead.