Abstract: A welding machine includes a welding power supply that generates a welding waveform during a welding operation, an internal combustion engine, and a generator that is operatively connected to the welding power supply to supply electrical energy to the welding power supply. The generator includes a rotor shaft driven by the internal combustion engine, and an end casting located at an end of the generator opposite the internal combustion engine. A rotary screw compressor is mounted to the end casting of the generator. A clutch mechanism couples the rotor shaft to the rotary screw compressor to selectively drive the rotary screw compressor by the rotor shaft.

Abstract: A welding machine includes a welding power supply that generates a welding waveform during a welding operation, an internal combustion engine, and a generator that is operatively connected to the welding power supply to supply electrical energy to the welding power supply. The generator includes a rotor shaft driven by the internal combustion engine, and an end casting located at an end of the generator opposite the internal combustion engine. A rotary screw compressor is mounted to the end casting of the generator. A clutch mechanism couples the rotor shaft to the rotary screw compressor to selectively drive the rotary screw compressor by the rotor shaft.

Abstract: A welding system and welding helmet is provided, where the welding helmet is capable of providing an image representative of information from an associated welding operation where the image appears as a head-up display (HUD) in the welding helmet. The helmet displays the information at a focal point which coincides with a working distance of a welding operation so that a user need not change his/her focus during a welding operation. The helmet also comprises a microphone to allow for audio instruction to be provided to a welding power supply to change settings.

Abstract: Welding helmets, systems, and kits providing real-time fume exposure monitoring and warning capability during an arc welding process. A welding helmet configured to protect the head of a user during a welding process is configured with an intelligent warning apparatus and an air-sampling pick-up and output port. The air-sampling pickup and output port connects to a proximal end of an air sampling tube for sampling breathable air within the welding helmet, and a distal end of the air-sampling tube connects to an air-sampling in-take port of an external aerosol monitoring device. The intelligent warning apparatus communicates with the aerosol monitoring device to receive air sample output data from the aerosol monitoring device, and to process the air sample output data to generate warning data and/or warning signals based on preset exposure level set points and/or exposure warning operating modes.

Abstract: Welding helmets, systems, and kits providing real-time fume exposure monitoring and warning capability during an arc welding process. A welding helmet configured to protect the head of a user during a welding process is configured with an intelligent warning apparatus and an air-sampling pick-up and output port. The air-sampling pickup and output port connects to a proximal end of an air sampling tube for sampling breathable air within the welding helmet, and a distal end of the air-sampling tube connects to an air-sampling in-take port of an external aerosol monitoring device. The intelligent warning apparatus communicates with the aerosol monitoring device to receive air sample output data from the aerosol monitoring device, and to process the air sample output data to generate warning data and/or warning signals based on preset exposure level set points and/or exposure warning operating modes.

Abstract: A welding system and welding helmet is provided, where the welding helmet is capable of providing an image representative of information from an associated welding operation where the image appears as a head-up display (HUD) in the welding helmet. The helmet displays the information at a focal point which coincides with a working distance of a welding operation so that a user need not change his/her focus during a welding operation. The helmet also comprises a microphone to allow for audio instruction to be provided to a welding power supply to change settings.

Abstract: The invention described herein generally pertains to a system and method for detecting a moisture with a flux used in a welding process. A sensor is employed with a flux source that supplies a welding operation or process in which the sensor detects a moisture level with a flux within the flux source. A monitor component is configured to receive or aggregate data from the sensor, wherein the data relates to the moisture level associated with a flux supply or a portion of flux.

Abstract: A system and method for edging a deposit layer in any of cladding, building up, and hard-facing applications is provided. The system includes a high intensity heat source that heats a workpiece and creates a molten puddle. The system also includes a wire feeder that feeds a wire to the molten puddle. The wire melts in the molten puddle and creates a bond with the molten puddle to form the deposit layer on the workpiece. The system further includes an edging system that has at least one laser that emits a laser beam that impinges on at least one of a surface area and an edge area of the deposit layer to modify the deposit layer. The laser modifies the deposit layer by at least one of melting and vaporizing at least a portion of the surface area and/or the edge area.

Abstract: The invention described herein generally pertains to a system and method for detecting a moisture with a flux used in a welding process. A sensor is employed with a flux source that supplies a welding operation or process in which the sensor detects a moisture level with a flux within the flux source. A monitor component is configured to receive or aggregate data from the sensor, wherein the data relates to the moisture level associated with a flux supply or a portion of flux.

Abstract: A system and method for edging a deposit layer in any of cladding, building up, and hard-facing applications is provided. The system includes a high intensity heat source that heats a workpiece and creates a molten puddle. The system also includes a wire feeder that feeds a wire to the molten puddle. The wire melts in the molten puddle and creates a bond with the molten puddle to form the deposit layer on the workpiece. The system further includes an edging system that has at least one laser that emits a laser beam that impinges on at least one of a surface area and an edge area of the deposit layer to modify the deposit layer. The laser modifies the deposit layer by at least one of melting and vaporizing at least a portion of the surface area and/or the edge area.

Abstract: A system and method for using gas flow to control a molten puddle in out-of-position applications is provided. The system includes a high intensity energy source configured to heat at lease one workpiece to create a molten puddle and a housing assembly configured to supply a gas over the molten puddle in order to minimize sagging of the molten puddle in the out-of-position applications. The system also includes a gas source that is configured to supply the gas. The gas source is operatively connected to the housing assembly. The pressure of the gas in the housing assembly is in a range of 15 psi to 35 psi. The method includes heating at least one workpiece to create a molten puddle and supplying a gas over the molten puddle via a housing assembly in order to minimize sagging of the molten puddle in the out-of-position applications.

Abstract: A system and method for use in brazing, cladding, building up, filling, overlaying, welding, and joining applications is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle and a feeder system that includes a wire feeder configured to feed a consumable to the molten puddle. The system also includes an induction system which receives the consumable and induction-heats a length of the consumable prior to that part of the consumable entering the molten puddle. The method includes heating at least one workpiece to create a molten puddle and feeding a consumable to the molten puddle. The method also includes induction-heating a length of the consumable prior to that part of the consumable entering the molten puddle.

Abstract: A plasma arc torch comprises relatively displaceable electrode and nozzle components having first and second positions relative to one another in which the electrode respectively contacts the nozzle and is spaced an operating distance therefrom. Arrangements are disclosed for relatively displacing the electrode and nozzle between the first and second positions thereof with a pre-determined force of engagement therebetween in the first position, and without having to interrupt the flow of arc gas and/or the flow of arc current during such relative displacement. A torch start up safety test procedure is performed by sequentially displacing the electrode and nozzle between the two positions thereof, sensing for appropriate open and closed circuit conditions therebetween, and enabling the creation of a pilot arc only when a pre-determined sequence of circuit conditions is sensed.

Abstract: A plasma arc torch comprises relatively displaceable electrode and nozzle components having first and second positions relative to one another in which the electrode respectively contacts the nozzle and is spaced an operating distance therefrom. Arrangements are disclosed for relatively displacing the electrode and nozzle between the first and second positions thereof with a pre-determined force of engagement therebetween in the first position, and without having to interrupt the flow of arc gas and/or the flow of arc current during such relative displacement. A torch start up safety test procedure is performed by sequentially displacing the electrode and nozzle between the two positions thereof, sensing for appropriate open and closed circuit conditions therebetween, and enabling the creation of a pilot arc only when a pre-determined sequence of circuit conditions is sensed.