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.

Abstract: A pulse welding welder is provided which provides a pulse welding waveform to a workpiece to be welded. The welding waveform has a plurality of welding cycles and each of the cycles has a droplet transfer peak pulse and a background portion with a first polarity and an opposite polarity portion which precedes the droplet transfer peak pulse and is after the background portion.

Abstract: Embodiments of the present invention comprise a system and method to weld or join coated materials using an arc welding system alone, or in combination with a hot wire system, where the arc welding system uses a welding current having an AC current portion to build a droplet for transfer to the workpiece. In further embodiments, the workpiece is coated with a material, such as zinc, and the arc welding system uses an AC welding waveform which is capable of welding coated workpieces with little or no porosity or spatter and can achieve enhanced performance. Additional embodiments use an enhanced electrode to provide optimum porosity performance. Such embodiments allow for the welding of coated material with little or no porosity and spatter, and at a high welding rate.

Abstract: Embodiments of the present invention comprise a system and method to weld or join coated materials using an arc welding system alone, or in combination with a hot wire system, where the arc welding system uses a welding current having an AC current portion to build a droplet for transfer to the workpiece. In further embodiments, the workpiece is coated with a material, such as zinc, and the arc welding system uses an AC welding waveform which is capable of welding coated workpieces with little or no porosity or spatter and can achieve enhanced performance. Additional embodiments use an enhanced electrode to provide optimum porosity performance. Such embodiments allow for the welding of coated material with little or no porosity and spatter, and at a high welding rate.

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 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 providing controlled AC arc welding processes. In 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 a consumable electrode to a workpiece and further aids in the maintaining or the re-establishing of an arc between the consumable electrode and the workpiece when a molten metal ball is transferred.

Abstract: A method of controlling a power source includes providing a power supply module. The power supply module includes a first circuit that has at least one first switch. The first circuit is configured to provide a welding current to an electrode of a welding system. The power supply module also has a second circuit that includes a load that is operatively connected to at least one second switch. The second circuit is configured to provide the welding current to the electrode through the load. The method also includes controlling the at least one first switch such that the welding current flows through the at least one first switch and to the electrode during a ramp up portion of a welding waveform and such that no current flows through the at least one first switch during a ramp down portion of the welding waveform. The method further includes controlling the at least one second switch such that the welding current flows through the load and to the electrode during the ramp down portion of the welding waveform.

Abstract: A system and method of hybrid welding a dual fillet weld. The system includes a laser system that leads a first torch and preheats at least one workpiece. The system also includes a first welding power supply that supplies a first welding waveform to a first wire via the first torch. The first welding waveform creates a first arc between the first wire and the at least one workpiece. The system further includes a second welding power supply that supplies a second welding waveform to a second wire via a second torch. The second welding waveform creates a second arc between the second wire and the at least one workpiece. A controller in the system is operatively coupled to the first power supply, the second power supply and the laser system. The controller synchronizes the first welding waveform and the second welding waveform such that welding current pulses of the second welding waveform at the second torch are not in phase with welding current pulses of the first welding waveform at the first torch.

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.

Abstract: A system and method of hybrid welding a dual fillet weld. The system includes a laser system that leads a first torch and preheats at least one workpiece. The system also includes a first welding power supply that supplies a first welding waveform to a first wire via the first torch. The first welding waveform creates a first arc between the first wire and the at least one workpiece. The system further includes a second welding power supply that supplies a second welding waveform to a second wire via a second torch. The second welding waveform creates a second arc between the second wire and the at least one workpiece. A controller in the system is operatively coupled to the first power supply, the second power supply and the laser system. The controller synchronizes the first welding waveform and the second welding waveform such that welding current pulses of the second welding waveform at the second torch are not in phase with welding current pulses of the first welding waveform at the first torch.

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 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 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 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 manufacture closed cooling channels employing a high intensity energy source to and a filler substrate material on which a layer is formed before the removal of the substrate material.

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 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: Systems and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance.