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 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 while manipulating the feed speed and/or direction of the electrode. A cycle of the electric arc 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 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.

Abstract: A system and method is provided for monitoring and displaying real time information regarding the inductance of the welding circuit, such that a user can monitor the performance of a power supply to determine if the system inductance is adversely affecting the operation of the power supply, and where the system can change the output signal based on the detected system inductance.

Abstract: A power supply with a waveform control function is provided. The power supply includes a waveform type selector that selects a desired shape for an output waveform and a setpoint selector that sets an output setpoint for the power supply. The power supply further includes a waveform generator that generates a reference waveform signal. The waveform generator includes a target generation circuit that generates a plurality of target values corresponding to the reference waveform signal. The waveform generator also includes a transition circuit that performs a series of transitions between the plurality of target values to generate the reference waveform signal, and a ramp circuit that controls a ramp speed of at least one transition of the series of transitions based on the desired shape. The generation of a target value corresponding to a peak value of the reference waveform signal is based on at least the output setpoint.

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 plasma arc cutting system and method is providing which provides a fixed arc start current until separation occurs between the torch nozzle and electrode. After separation the current is dropped to a low current level for a period of time and then current pulses are provided until a work current is detected in a work piece to be cut.

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: Methods and system of the present invention include hot-wire welding system used in combination with arc welding systems, where the welding system initiates an arc clearing routine in hot-wire welding system. The arc clearing routine includes detection of an arc and then skipping a complete pulse of the hot-wire waveform and initiating the next pulse to determine is consumable separation still exists. Follow-on pulses are repeatedly initiated until it is determined that consumable separation does not exist, at which time the hot-wire operation is continued.

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 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 system and method to correct for height error during a robotic welding additive manufacturing process. One or both of a welding output current and a wire feed speed are sampled during a robotic welding additive manufacturing process when creating a current weld layer. A plurality of instantaneous contact tip-to-work distances (CTWD's) are determined based on at least one or both of the welding output current 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 weld layer.

Abstract: The subject innovation relates to engine driven welding systems and methods regulating an environmentally controlled electrode compartment within storage constraints to maintain electrode integrity regardless of environmental factors outside the container. Various sensors and controllers which directly or indirectly provide input to the engine of the engine driven welder are used to facilitate such regulation, which is conducted at least in part using the engine itself.

Abstract: A welding system includes at least one high intensity energy source to create a weld puddle during a root pass on a narrow joint of a workpiece with a clad layer. The system also includes a controller to control a weld ramp out process such that, as the molten puddle advances to a start of an existing root pass weld, the controller at least one of decreases an energy output of the at least one high intensity energy source and reduces an interaction time between the at least one high intensity energy source and the weld puddle. After completion of the root pass, a thickness of a root pass weld in a region that is at or near the start point of the existing root pass weld is in a range of 100 percent to 130 percent of a nominal root pass thickness of a remainder of the root pass weld.

Abstract: Systems and methods for affecting an appearance of a deposited weld bead by modulating one or more welding parameters. For example, an electrode negative portion of a welding output current may be modulated to affect the appearance of a deposited weld bead. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with an electrode negative portion of a welding output current to affect a deposited weld bead appearance. Two or more welding processes may be interleaved with each other at a specified modulation frequency to affect a deposited weld bead appearance. One or more welding parameters may be modulated based on a welding travel speed to provide a consistent appearance of a deposited weld bead.

Abstract: The invention described herein generally pertains to a system and method for generating a negative polarity welding output current waveform to control a welding process. An electric arc welding system generates an electric welding waveform with portions in a negative polarity. A cycle of the electric welding waveform includes a background current phase, a short clearing ramp phase after the background current phase, a peak current phase, and a tail-out current phase of the electric welding waveform, wherein the peak current phase provides a negative peak current level, the tail-out current phase provides a monotonically increasing tail-out current level toward the positive background current level, and the short clearing ramp phase provides a decreasing current level in a positive polarity of current for the electric welding waveform.

Abstract: Welding systems are presented, in which a single power source provides a first DC output to a plurality of digital waveform controlled chopper modules. Welding modules are also disclosed for converting an input DC signal to a welding signal, which are comprised of a down-chopper for providing a welding signal waveform according to a pulse width modulated switching signal, along with a digital waveform controller providing the switching signal according to a desired waveform.

Abstract: A welding power supply and method are provided with a single welding mode in its controller such that the power supply can change from full DCEN output to AC output to a full DCEP output without having to change welding modes.

Abstract: The invention described herein generally pertains to a method for improved droplet detachment detection in a welding process in which a derivative of at least one welding parameter over time is used to detect droplet detachment from the wire during a welding operation based identification of a peak signature.

Abstract: The invention described herein generally pertains to a system and method related to influencing a direction of an arc within a welding operation. Within a hot wire welding operation, an arc is generated between an electrode and a workpiece and a welding wire is energized while being supplied to a puddle formed by the electrode in order to deposit the liquefied welding wire onto the workpiece. A welder system and/or method is provided that controls a direction of the arc based on at least one of a polarity of the welding wire (via a power supply that energizes the welding wire), a location of the welding wire in proximity to the arc, a synchronization and/or de-synchronization of a polarity of the welding wire with the electrode, an activation and/or a de-activation of energizing of the welding wire, or a combination thereof.

Abstract: An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece, where the pulses and a background current defining a series of weld cycles. A wave shape generator defines the shape of the pulses and the background current including a controlled ramp up and/or ramp down in each of said cycles, and a circuit to change the shapes of the pulses and/or background current in a repeating pattern in each of the weld cycles, including a negative current in at one of said pulses. The shape change in a cycle can be between first and second shapes or by a rhythmic AC modulation.