Abstract: A system and method provide gasless, mechanized, field welding of an exterior of a tubular structure such as a pipeline, without the need for an enclosure. An embodiment consolidates some of the welding equipment on a skid for ease of transport to and from a remote worksite. The gasless weld may be achieved despite the presence of wind, by precisely controlling an arc voltage as disclosed. The footprint and weight of the system may be minimized, along with the associated labor, expense, and environmental impact otherwise incurred by conventional welding techniques using enclosures.

Abstract: Apparatus and methods are provided for an engine driven welding-type power system that includes an engine to drive an electric generator to provide a first power output, and a removable welder having an energy storage device to provide a second power output. The system includes a housing having a dock to store a removable welder. While stored within the dock, the energy storage device is recharged by the first power output. Once removed from the dock, the removable welder is configured to operate independently of the power system.

Abstract: The invention relates to an electric arc-welding welding head comprising a contact device and one or more wire feeder units, the contact device encompassing an electrode assembly, the electrode assembly comprising at least two fusible continuously-fed wire electrodes arranged in a contact device. An electrically insulated duct is provided for electric insulation of at least one of the electrodes so that the electrode is electrically insulated from other electrodes in the electrode assembly. The invention also relates to an electric arc-welding contact device and an electric arc-welding welding head assembly.

Abstract: A welding torch includes an inner tube of a helically wound wire to define a passage for a welding wire, a conduit in which the inner tube is inserted, the conduit having a curved portion, a torch body including a tip portion and a nozzle, a torch holder having a gas supplying member that supplies a shield gas into a space between the inner tube and the conduit, a feed unit provided upstream of the torch holder to feed the welding wire forward to or backward from the inner tube, and a sealing mechanism for preventing a reverse flow of the shield gas to the feed unit. A gap is defined between the adjacent wires of the inner tube allowing the shield gas to flow therethrough, and permitting wear debris generated by abrasion of the welding wire sliding in the inner tube to be ejected out from the nozzle.

Abstract: The present application discloses an electric welder, and relates to a field of an electric welding equipment. The electric welder includes a shell, a welding barrel, a controller and a welding wire feeder; the shell includes a handheld part, and the welding barrel, the controller and the welding wire feeder are installed in the shell; the welding wire feeder is configured for conveying the welding wire into the welding barrel; the controller is configured for controlling a start and a stop of the welding wire feeder and an arcing of the welding wire. The welding barrel, the controller and the welding wire feeder are installed in the shell to form an integral structure, which makes the welder more convenient to carry. In addition, by providing the welding wire feeder, a frequent replacement of the welding rod during a welding process is reduced, and the overall operation is more convenient.

Abstract: A weld system includes: a robot control module configured to actuate a robot and move a welder along a joint of metal workpieces during welding, the welder being attached to the robot; a weld control module configured to, during the welding, apply power to the welder, supply a shield gas, and supply electrode material; a vision sensor configured to, during the welding, optically measure distances between the vision sensor and locations, respectively, on an outer surface of a weld bead created along the joint by the welder; and a weld module configured to: determine a strength of the weld bead at a location based on: the distances at the location along the joint; and at least one parameter from at least one of the robot control module during the welding, the weld control module during the welding, and a sensor configured to capture data of the welding during the welding.

Abstract: A contact tip assembly having an electric contact unit containing a contact tip with an electric energy source, where the electric contact unit is positioned at a distance away from the outlet opening of a guide.

Abstract: The present disclosure relates to a system of modular functional blocks that may be used to facilitate easy assembly of a welding head assembly in any one of a wide variety of configurations to allow for distribution of welding wire, gas, cooling fluid and other media throughout an interconnected assembly of the modular functional blocks. As such, the modular functional blocks can be mixed and matched into any desired configuration as needed depending on the welding process being undertaken. The modular functional blocks may be in the form of one or more different welding wire delivery blocks, gas delivery blocks, cooling water delivery blocks, shim plates, end plates, shield cup, cover plates, insulating plates, etc.

Abstract: There is provided an arc welding control method of alternating a feeding rate of a welding wire between a forward feeding period and a reverse feeding period, controlling a welding voltage based on a voltage setting value and alternating short-circuiting periods and arc periods to perform welding. In the arc welding control method a cycle of the feeding rate is changed based on the voltage setting value.

Abstract: The wire feed mechanism includes a feed roll, a pressure roll, a pressure arm, and a pressure mechanism. The feed roll rotates around a rotation axis. The pressure roll is displaceable relative to the feed roll. The pressure arm has a first end and a second end that are separate from each other, and rotatably supports the pressure roll. The pressure mechanism engages with the pressure arm so that a pressure force is applied from the pressure roll to the feed roll with a wire held between the feed roll and the pressure roll. A force-receiving portion is provided at an end of the pressure arm. When the pressure roll presses the feed roll, the pressure mechanism applies a force to the force-receiving portion in a direction that is substantially parallel to the direction in which the wire is fed.

Abstract: An arc welder cable includes a resiliently flexible hose, an intermediate sheath, a plurality of conductors, and an outer sheath. The hose defines an axial passageway configured to permit passage of a welding wire and a shielding gas therethrough. The intermediate sheath circumscribes the hose such that the hose is disposed radially within the intermediate sheath. The intermediate sheath is made from an electrically-insulative material and is in sealing contact with an outer surface of the hose. The conductors are disposed circumferentially about the intermediate sheath and disposed radially outward of the intermediate sheath. The conductors extend along the intermediate sheath in a helical manner. The conductors are made from an electrically-conductive material. The outer sheath is made from an electrically-insulative material and circumscribes the conductors such that the conductors, the intermediate sheath, and the hose are disposed radially within the outer sheath.

Abstract: Systems, methods, and apparatus for a structural propellant for ion rockets (SPIR) are disclosed. In one or more embodiments, a method for in-space propulsion of a spacecraft involves removing, by a removal device, a portion of a structure of the spacecraft. The method further involves feeding, by the removal device, the portion into a Hall thruster system. Further, the method involves utilizing, by the Hall thruster system, the portion as propellant to produce thrust. In one or more embodiments, the structure is an upper stage of the spacecraft. In at least one embodiment, the upper stage comprises at least one structural support and/or at least one upper stage housing. In some embodiments, the structure is manufactured from magnesium, bismuth, zinc, and/or indium.

Abstract: An arc welding power supply supplies power to a welding wire functioning as a discharge electrode to generate an arc from an electrode distal end of the welding wire and perform arc welding on a welded article. The arc welding power supply includes an output control unit that adjusts the power supplied to the welding wire to a power value suitable for arc welding. A feed control unit cyclically changes a feeding speed of the welding wire. The feeding speed includes a forward feeding speed and a rearward feeding speed. An amplitude control unit cyclically changes an amplitude of the feeding speed of the welding wire to cyclically vary an average arc length.

Abstract: The invention relates to a method for submerged arc welding comprising the steps of guiding a first hot wire (4; 4a, 4b) towards a work piece and guiding a cold wire (22; 22a, 22b) at a variable feed speed. The method further comprises the steps of continuously measuring, during a welding phase, at least a first active welding parameter related to at least said first hot wire (4; 4a, 4b) adjusting the cold wire (22; 22a, 22b) feed speed in dependence on at least first active welding parameter variations, to maintain high welding stability and high weld quality. The invention also relates to a system (9) for carrying out the method. The system (9) comprises hot wire feeding means (150) for feeding a first hot wire (4; 4a, 4b) towards a work piece and cold wire feeding means (35) for feeding a cold wire (22; 22a, 22b) at a variable cold wire (22; 22a, 22b) feed speed and a control unit (31) for controlling the second wire feeding means (35).

Abstract: A telepresence robot uses three separately controlled omni-wheels and a computer processing arrangement to reposition the robot based on received positional signals. The telepresence robot captures and transmits visual information of a limited field of view and visual information of a broad field of view. The visual information is received and displayed on a remote input device and portions of the displayed information are selected to send an appropriate signal to reposition the robot based on the selected portion. A method of remotely controlling a telepresence robot is also disclosed.

Abstract: A welding system including a fine tuning knob and a coarse adjustment knob for setting a weld wire feed speed are provided. The welding system may include a welder having the coarse adjustment knob and a spool gun having the fine tuning knob. A user may adjust the knob on the welder to set a coarse adjustment wire feed speed and may adjust the knob on the spool gun to fine tune the wire feed speed setting.

Abstract: A welding diffuser and contact tip assembly is provided for use with a welding apparatus. The assembly includes a diffuser with an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser, and a contact tip coupled to the diffuser. The contact tip includes a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an angled outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to thereby discharge the debris to an exterior of the diffuser. In one example, the rear portion of the contact tip includes an angled outer surface defining the diffuser insert.

Abstract: A telepresence robot uses three separately controlled omni-wheels and a computer processing arrangement to reposition the robot based on received positional signals. The telepresence robot captures and transmits visual information of a limited field of view and visual information of a broad field of view. The visual information is received and displayed on a remote input device and portions of the displayed information are selected to send an appropriate signal to reposition the robot based on the selected portion. A method of remotely controlling a telepresence robot is also disclosed.

Abstract: A welding gun includes a handle portion comprising a motor configured to move electrode wire through the welding gun. A diffuser comprises an interior chamber and a plurality of openings defining exit passages from the interior chamber to an exterior of the diffuser. A barrel is located between the diffuser and the handle portion and supplies to the diffuser from the handle portion. A contact tip extends from the diffuser and comprises a front portion, a rear portion, and a contact tip bore extending therethrough configured to receive the electrode wire. A diffuser insert is disposed within the interior chamber of the diffuser, including an insert bore extending therethrough configured to receive electrode wire, and an outer surface configured to direct debris from within the interior chamber of the diffuser towards exit passages to discharge the debris. The handle portion is configured to direct a flow of the shielding gas over the motor to cool the motor.

Abstract: In a multi-electrode welding torch, electrodes (2) are configured into a shape that has an arc-shaped curved surface area (R) in at least a portion of a cross-section thereof that is orthogonal to the longitudinal direction thereof. Collets (4) are each provided with a groove portion (4a) in which an electrode (2) is fitted, and whose inner wall surfaces (4b) come into contact in a plurality of locations with the curved surface area (R) when viewed in the longitudinal direction of the electrode (2).

Abstract: A wire feeder includes a wire feeder housing that may enclose one or more drive rollers rotatably connected with respect to the wire feeder housing for engaging welding wire. The one or more drive rollers may be adjustable and adapted to drive the welding wire to a welding gun connected to the wire feeder. A drive motor is incorporated for delivering power for rotating the one or more drive rollers. Friction reducing devices, such as bearings, may be utilized and positioned between one or more driver rollers and the housing, where the bearings are electrically non-conducting for preventing the discharge of electrical energy across the bearing surfaces.

Abstract: A portable welding wire feeder including a plastic instrument case having a base and a lid which are injection molded; the lid defining an interior cavity and the base defining an interior base cavity, a chassis mounted in the base cavity and adapted to support a spool of weld wire, a wire feeder mounted within the base and adapted to feed wire from the spool to an exterior of the instrument case; and a tool box shaped to conform to the interior of the lid and reside therein.

Abstract: The present invention generally provides a welding cart including a frame including a base and at least one support extending over from the base; a mount supported on the support, the mount having a mounting surface on which a wire feeder is supported, the mounting surface is being configured to raise a first end of the wire feeder to support to the wire feeder at an angle, where the wire conduit extending from the wire feeder extends from a lower end of the wire feeder. According to another embodiment of the invention, the mount has a slopped mounting surface adapted to support a wire feeder.

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 mock welding unicoupon for a virtual welding system includes a first exterior surface and a second exterior surface perpendicular to the first exterior surface. The first exterior surface and the second exterior surface together provide a plurality of grooves configured for simulation of a plurality of different types groove welds on the mock welding unicoupon. A curved exterior surface is configured for simulation of a pipe fillet weld on the mock welding unicoupon. A magnet source is configured to generate a magnetic field around the mock welding unicoupon for tracking movements of a mock welding tool with respect to the mock welding unicoupon.

Abstract: A method and a welding device for performing a welding process on a workpiece by a welding torch, uses a melting welding wire, which is arranged on a wire coil and may be supplied to the welding torch via a hose package, wherein different welding wires and different welding parameters are used depending on the geometry of the workpiece. A welding wire formed by the different interconnected welding wires in lengths depending on the geometry of the workpiece is arranged on the wire coil, so the welding process may be performed without interruptions using the different welding wires and the different welding parameters by supplying to the welding torch the welding wire formed by the different interconnected welding wires from the wire coil.

Abstract: A welding head is provided. The welding head includes a bracket and a plurality of blocks coupled to the bracket. Each of the plurality of blocks has a contact tip. The contact tips are adapted to receive an electrode. Further, at least one of the plurality of blocks is capable of variable positioning relative to the bracket.

Abstract: A dual-weave welding system is disclosed. The system may have a first welding device configured to create a weld joint in a gap between two or more work pieces by moving a first welding component along a first weaving path. The system may also have a second welding device configured to create the weld joint in the gap by moving a second welding component along a second weaving path. The system may further have a controller that sends commands to control the movement of the first welding device and the second welding device.

Abstract: One embodiment of the present invention relates to a system for buried-arc welding with thru-the-arc seam tracking. Another embodiment of the present invention relates to a method for buried-arc welding with thru-the-arc seam tracking.

Abstract: A method for producing a welded joint between a high-strength aluminium alloy with a copper proportion as a first metal and a second metal, in which the welded joint is produced by CMT welding.

Abstract: In a method for controlling pulse arc welding where an arc is created between a wire and a base material, a pulse waveform different from the pulse waveform for steady-state welding is outputted when a predetermined time has passed since short-circuit welding control was started at arc start, and after a sufficiently large melt pool is formed, the pulse waveform for the steady-state welding is outputted. This reduces the generation of spatters after an arc is created and until the arc is stabilized.

Abstract: Hybrid welding apparatuses include a laser that produces a leading laser beam, and, an arc welder that produces a trailing backhand weld arc, wherein the leading laser beam and the trailing backhand weld arc are directed towards a common molten pool, and wherein the trailing backhand weld arc trails the leading laser beam as the leading laser beam progresses in a weld direction.

Abstract: A system and method for automatic detection of a connection of a spool gun to a welding system. In addition to automatically detecting connection of the spool gun, a system and method is provided for controlling the operation of the welding system based on the detection of the spool gun.

Abstract: An apparatus for feeding a wire. The apparatus includes at least one pair of rotatable rollers and at least one curved or curvable force-generating element. The at least one curved or curvable force-generating element is capable of applying a force via a proximal end of the at least one curved or curvable force-generating element to displace a first roller of the at least one pair of rotatable rollers towards a second roller of the at least one pair of the rotatable rollers to engage a wire there between. The apparatus further includes an adjustment mechanism operationally connected at a distal end of the at least one curved or curvable force-generating element to allow adjustment of the applied force.

Abstract: A system having a welding wire hub with a wire-specific interface. The wire-specific interface may be configured to enable mounting with a first wire spool and configured to prevent mounting with a second wire spool. In some embodiments, the first and second wire spools have different welding wire types.

Abstract: A system and method of welding stainless steel to copper is provided. The method includes providing a first workpiece composed of stainless steel and providing a second workpiece composed of copper. The method also includes heating by using a laser a root area of a joint created by the workpieces. The heating by the laser creates a keyhole in at least one of the first workpiece and the second workpiece. The method also includes providing a consumable electrode that is composed of nickel to the joint and creating an arc between the consumable electrode and the joint using a welding current. The preheating of the arc using the keyhole eliminates the need to preheat the second workpiece.

Abstract: A welding tool includes a first handle and a second handle. The welding tool also includes a torch nozzle holder configured to hold a nozzle of a welding torch therein, and to block the nozzle from extending therethrough. The welding tool includes a blade assembly positioned a predetermined distance from the torch nozzle holder. The blade assembly is configured to cut welding wire extending through the blade assembly to calibrate wire stickout from the welding torch to the predetermined distance.

Abstract: An arc welding method of the present invention controls a short-circuit current increasing gradient (di/dt), an inflection point at which the short-circuit current increasing gradient (di/dt) changes, the current in a peak period and in a base period, and the time of the peak period in accordance with a difference between a set voltage and an output voltage. This allows the output voltage to be matched with the set voltage, and stabilizes the arc. Thereby, a stable arc welding method can be implemented, even as a method for outputting a welding current based on a welding voltage.

Abstract: In a two-electrode welding method of the present invention, a leading electrode is used to perform gas-shielded arc welding and a trailing electrode is an energized filler. A trailing electrode wire protrudes from a guide lead or guide tip and is energized from an energizing tip. The distance between a welding surface and the energizing tip is 100 mm or more and 1500 mm or less. The distance between electrodes is 10 mm or less. The electric current of the leading electrode is 250 A or more, and the electric current of the trailing electrode is 10 A or more and 50% or less of the electric current of the leading electrode. The feeding speed of the trailing electrode wire is 20% or more and 50% or less of the feeding speed of the leading electrode wire.

Abstract: A system having a welding wire hub with a wire-specific interface. The wire-specific interface may be configured to enable mounting with a first wire spool and configured to prevent mounting with a second wire spool. In some embodiments, the first and second wire spools have different welding wire types.

Abstract: A method of monitoring and assessing contact tip useful life in a GMAW-pulse application. The pulse welding waveform includes current and voltage that periodically change between peaks and background. The welding current and voltage are measured on a series of repeated representative welds. The data that corresponds to the arc start and the arc stop of a weld is removed. The data is averaged for each representative weld, which corresponds to production of welded parts and/or usage of the contact tip. The deterioration of the contact tip is assessed based on one or more of (i) a decrease in the frequency of the peaks, (ii) an increase in the length of the background, and (iii) an increase in the occurrence of abnormal low voltage. The assessment is outputted as contact tip life data, and continuously fed to a controller or operator.

Abstract: The invention relates to a device for transporting a welding wire (13), comprising at least one pair of rollers (55) consisting of drive roller (32) and a pressure roller (31) and a device (28) which is used to clamp a welding wire (13), in addition to a roller, in particular a drive roller (32), an intermediate piece (49), a threading device (74), a automatically centering device (80) and a device (85) which is used to detect the transportation speed of the welding wire (13). The pressure roller (31) is mounted in a pivotable pressure lever (29) in order to produce the most smallest, compact and easy to handle wire transporting device (27) possible and the clamping device (28) comprises a clamping bar (37) which can be connected to the pressure lever (29) in order to fix and pressurize.

Abstract: A cored electrode having reduced moisture pick-up properties and which forms a weld bead with low diffusible hydrogen in a gas shielded electric arc welding process. The cored electrode includes a metal sheath and a fill composition. The fill composition includes titanium dioxide, slag forming agent and a sodium-silica-titanate compound.

Abstract: The invention provides a device for producing a connection grid with an integrated fuse. The device includes a means for supporting the connection grid, a laser head, and a nozzle for supplying fuse wire. The means for supporting the connection grid is a support having a housing that is suitable for receiving a portion of the fuse in the space formed between two symmetrical arms of the connection grid. The support having an overall shape of a hollow half-cylinder, by a curved base and two lateral ribs standing on the base, and an upper surface of which is turned down by chamfering of the housing side. The laser head and nozzle are mechanically connected to a system of robotized shafts.

Abstract: In a welding wire storage device for a welding system including a housing with a wire core surrounding the welding wire being arcuately arranged to lie freely in a free space of the housing, one end of the wire core is fixed in an end region of the housing and a measuring means is provided to detect the deflection of the wire core. In order to provide a very simple and compact structure for such a welding wire storage device, the wire core is displaceably mounted in a guide element on the opposite end region, and two coupling mechanisms, for connection with a wire guide hose for the wire core are arranged on the housing.

Abstract: The invention relates generally to welding and, more specifically, to welding wires for arc welding, such as Gas Metal Arc Welding (GMAW) or Flux Core Arc Welding (FCAW). In one embodiment, a tubular welding wire includes a sheath and a core. The tubular welding wire is configured to form a weld deposit on a structural steel workpiece, wherein the weld deposit includes less than approximately 2.5% manganese by weight.

Abstract: A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.

Abstract: A tele-presence system that includes a cart. The cart includes a robot face that has a robot monitor, a robot camera, a robot speaker, a robot microphone, and an overhead camera. The system also includes a remote station that is coupled to the robot face and the overhead camera. The remote station includes a station monitor, a station camera, a station speaker and a station microphone. The remote station can display video images captured by the robot camera and/or overhead camera. By way of example, the cart can be used in an operating room, wherein the overhead camera can be placed in a sterile field and the robot face can be used in a non-sterile field. The user at the remote station can conduct a teleconference through the robot face and also obtain a view of a medical procedure through the overhead camera.

Abstract: A system and method for controlling heating current for hot-wire processes in any of brazing, cladding, building up, filling, hard-facing 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. The system also includes a feeder subsystem that includes a wire feeder configured to feed a filler wire to the molten puddle, a first power supply configured to supply a first current through a first length of the filler wire, and a second power supply configured to supply a second current through a second length of the filler wire. The first current and the second current provide a power sufficient to resistance-heat the filler wire to at or near a melting temperature of the filler wire, and in some embodiment, the first power supply provides more than 50% of the power.

Abstract: A system and method for narrow groove welding is provided. The system includes at least one laser emitting a laser beam to heat at least one of a first workpiece and a second workpiece to create at least one molten puddle. The system also includes at least one wire feeder feeding at least one wire to the at least one molten puddle. An edge of the first workpiece and an edge of the second workpiece are configured such that an alignment of the workpieces forms a first groove and a second groove. The first groove and the second groove are formed on opposite sides of the workpieces. For each groove, its depth is 50% to 75% of a thickness of the first workpiece or the second workpiece, a gap width at a surface of the workpieces is 1.5 to 2 times a diameter of the at least one wire, and a sidewall angle is a range of 0.5 to 10 degrees with respect to a centerline of the respective groove.