Abstract: The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can house electrodes that allow deposition of material on a workpiece. At least a first set of electrodes and a second set of electrodes can be driven at different speeds. Moreover, welding arcs for one or more electrodes can be established based upon a predetermined order in which the predetermined order can be based on at least one of a location of the electrode head on the workpiece, a start of a welding process, and/or a stopping of a welding process.

Abstract: An electric arc welder and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode and a workpiece. The welder includes a short-detecting capability for detecting a short condition upon occurrence of a short circuit between the advancing electrode and the workpiece. The welder may also include a switching module in the welding circuit path of the welder having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module, for example.

Abstract: A system and method is provided. The system includes a high intensity energy source to create a molten puddle on a surface of a workpiece and a wire feeder that feeds a wire to the molten puddle via a contact tube. The system also includes a power supply that outputs a first heating current during a first mode of operation and a second heating current during a second mode of operation. The system further includes a controller that initiates the first mode of operation in the power supply to heat the wire to a desired temperature and switches the power supply from the first mode of operation to the second mode of operation to create a micro-arc. The second mode of operation provides at least one of an increased heat input to the molten puddle and an increased agitation of the molten puddle relative to the first mode of operation.

Abstract: Systems and methods for providing controlled AC TIG arc welding processes is provided. In AC TIG arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from consumable to a workpiece, via an arc generated by a tungsten electrode, and further aids in the maintaining or the re-establishing of an arc between the tungsten electrode and the workpiece during welding.

Abstract: A method and a system for forming a root pass weld for a root pipe joint. A substantially periodic electric welding waveform is generated and a series of electric arc pulses are generated between an advancing welding electrode and a root pipe joint in response to the electric welding waveform. The electric welding waveform includes a base cycle having a background current phase providing a background current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and at least one heat-increasing current pulse during the background current phase providing a heat-increasing current level being above the background current level.

Abstract: An electric arc welder and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode and a workpiece. The welder includes a short-detecting capability for detecting a short condition upon occurrence of a short circuit between the advancing electrode and the workpiece. The welder may also include a switching module in the welding circuit path of the welder having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module, for example.

Abstract: An electric arc welding device for performing a pulse welding process by a current between an advancing electrode and workpiece where the welder comprises a short detecting circuit for creating a short signal upon occurrence of a short circuit between the advancing electrode and the workpiece and a boost circuit to create a plasma boost pulse after the short circuit is cleared during the time period when the welder is not outputting the peak pulse current. The peak pulse current to background current ratio is high and the duration of the peak pulse is short.

Abstract: The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can include a rectangular-shaped first contact bar and a rectangular-shaped second contact bar that can be affixed to one another with an assembly connective means in order to encase a plurality of electrodes therebetween. The second contact bar can include a set of grooves in which each groove can correspond to an electrode to provide guidance during a welding procedure.

Abstract: A system and method is provided for narrow groove joining of metals. The method includes feeding a wire to a weld joint formed by the metals to be joined and transmitting a welding current through a length of the wire. The method also includes creating a molten puddle in the weld joint with the welding current. The method further includes performing a low heat transfer process on the wire for a predetermined low heat duration to transfer a first portion of the wire to the molten puddle, and performing a high heat transfer process on the wire for a predetermined high heat duration to transfer a second portion of the wire to the molten puddle. The low heat transfer process creates the molten puddle at a root of the weld joint. The high heat transfer process creates an arc that climbs sidewalls of the weld joint and the molten puddle follows the arc up the sidewalls to a top of the weld joint.

Abstract: A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on one of a desired RMS voltage set point and a desired RMS voltage range. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion 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 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: The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can include a rectangular-shaped first contact bar and a rectangular-shaped second contact bar that can be affixed to one another with an assembly connective means in order to encase a plurality of electrodes therebetween. The second contact bar can include a set of grooves in which each groove can correspond to an electrode to provide guidance during a welding procedure.

Abstract: A system and method for controlling a hybrid welding process. An integrated hybrid welding power source includes a first power supply for providing a first welding output and a second power supply for providing a second welding output. The first power supply and the second power supply are operatively connected to coordinate the first welding output with the second welding output in real time while operating concurrently.

Abstract: There is provided an improved TIG welder comprising a power source for performing an AC TIG welding process across an electrode and a workpiece with a controller for creating an AC waveform. The controller having a synergic input device with an input for receiving a signal level representing a desired set current for the welding process and an output signal determining an aspect of the waveform and representing a non-linear relationship between peak positive current and peak negative current for certain desired set welding currents.

Abstract: The invention described herein generally pertains to a system and method related to energizing a welding wire based on a location of an electrode at an edge on a workpiece. An edge detector can be configured to identify an edge on the workpiece during a welding operation and a controller can be configured to mange a temperature of a puddle formed by the electrode by adjusting one or more welding parameters. The welding parameters can be, but are not limited to, an energizing of the welding wire, a wire feed speed, a temperature of a high intensity heat source (e.g., arc, a sub arc, a tungsten inert gas (TIG) arc, a metal inert gas (MIG) arc, a laser, a plasma arc, a metal core, or a flux core), movement speed, among others.

Abstract: A system and method for re-igniting and stabilizing an arc is provided. The system includes an output system that provides an output waveform, which includes a positive period and a negative period. The positive period includes a positive decay period prior to a transition to the negative period, and the negative period includes a negative decay period prior to a transition to said positive period. The system further includes an inductive discharge and stabilizing system, which includes at least one inductor. The at least one inductor re-ignites an arc between an electrode and a workpiece during the transition period from the positive period to the negative period and the transition period from the negative period to the positive period. The at least one inductor also provides a stabilizing current to stabilize said arc during at least a portion of said positive period and at least a portion of said negative period.

Abstract: A system and method of electric arc welding that includes a welding apparatus having a plurality of welding machines, e.g., tandem welding, and a synchronizing controller. The synchronizing controller controls the phase relationship of the welding waveforms associated with the welding machines. Portions of the welding waveforms can be modified to include a short-clearing routine that minimizes spatter. The synchronizing controller modifies portions of the welding waveforms such that the short-clearing intervals begin at different times to avoid interference between the signals associated with short-clearing.

Abstract: The invention described herein generally pertains to a system and method for a voltage sense lead being disposed on or within a welder gun in a hot wire application (e.g., hot wire laser, hot wire hybrid, and the like) to monitor voltage across the electrode. In this manner, resistive heating can be regulated to ensure that the wire and weld pool (e.g., puddle) temperature are within a desired range. The voltage sense lead can be incorporated into a welder gun or onto a welder gun in order to mitigate inaccuracies and voltage drops resultant of a cable connecting the welder gun to the wire feeder of a hot wire system.

Abstract: The invention provided is a system and method for welding or cladding using a strip electrode which is capable of delivering a desired chemistry, where the strip electrode contains an alloying or flux material. In embodiments, the strip electrode has at least two bulge portions separated by a web portion where the bulge portions have a larger thickness than the web portions. Other embodiments deliver each of a strip electrode and a cored electrode to the same puddle, while the electrodes make contact with each other before the puddle and share the deposition current.