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: 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 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 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: 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.

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: 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: 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 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 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 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.