Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: A hot-wire and arc welding system and method. The system includes an arc welding power supply to supply a welding waveform. The welding waveform includes a plurality of welding pulses, with each welding pulse having a peak welding current level. The system also includes a hot-wire power supply to supply a heating waveform. The heating waveform includes a plurality of heating pulses, with each heating pulse having a peak heating current level. A controller, which is operatively connected to the arc welding power supply and the hot-wire power supply, synchronizes the plurality of welding pulses and the plurality of heating pulses such that at least a portion of the peak welding current level overlaps with at least a portion of the peak heating current level.

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: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

Abstract: The invention includes a wire feed system that is used within a welder, the system having a forward drive roll that rotates in a first direction, a reverse drive roll that rotates in a second direction, which is opposite the first direction, wherein the forward drive roll and the reverse drive roll are both located on a first side of a wire, a first idle roll disposed opposite the forward drive roll, a second idle roll disposed opposite the reverse drive roll, wherein the first idle roll and the second idle roll are located on a second side of the wire, an arm that pivotally couples the first idle roll to the second idle roll, and an actuator that displaces the first idle roll to engage with the forward drive roll to advance the wire or displaces the second idle roll to engage with the reverse drive roll to retract the wire based upon a predetermined condition.

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: The subject embodiments relate to a retractable wire feed system used within a welder, which include a friction-drive system disposed on a first side of a wire, an idle drive roll located opposite the friction-drive system on a second side of a wire, wherein the friction-drive system advances the wire through a welding nozzle toward a workpiece, and a brake, which is applied to retract the wire when a predetermined condition is met.

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: Systems and methods consistent with embodiments of the present invention are directed to depositing a consumable onto a workpiece using a hot-wire welding technique which employs a combination of hot wire and arc welding. The waveform creates arc events during the hot wire welding operation to add/control heat in the welding process. The hot-wire welding process can be used by itself, with a laser or in conjunction with other welding processes.

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 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: Nonlinear adaptive welders and power source controls are provided along with welding methods method for regulating a welding process, in which one or more welding waveform parameters are adapted in nonlinear fashion based on measured welding process feedback information.

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 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 method and system to weld or join coated workpieces using an arc welding operation and at least one hot wire, resistance heated wire. Each of the arc welding and hot wire operation are directed to the same puddle. However, the arc welding operation is offset out of the joint from the hot wire operation, where the hot wire is directed into the joint.

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.