Abstract: A retaining head for a MIG welding device includes a contact tip mounting end, an opposite retaining head mounting end, and a throughbore extending from one of the ends to the other end. A deflector is disposed along the throughbore and is adjustable for imparting a bend in welding wire passing through the throughbore. The deflector provides a straight wire contour for the welding wire that is fed out of the welding torch, while maintaining sufficient contact force between the welding wire and the contact tip. The deflector also reduces the effect of wire twist on the contact point between the welding wire and the contact tip.

Abstract: A contact tip is provided for wire welding applications. The contact tip includes one or more conductive brushes fitted to a conductive contact tip body. Fibers of the brush extend into a passageway traversed by welding wire in operation. Electrical current is transmitted to the brush assembly and through the brush fibers to the welding wire. The fibers may transmit the current directly and also may enhance contact of the welding wire with one or more walls of the contact tip. Improved electrical contact and weld quality are obtained.

Abstract: The present invention discloses novel metal compositions predominantly composed of copper, nickel or nickel-cobalt, and tin for use in Mig welding and other application methods to form electrically conductive, oxidation resistant, and wear resistant welding contact surfaces.

Abstract: A contact tip suitable for electric arc welding has a consumable electrode. The contact tip has a body which defines a bore through which the electrode is able to pass to enable electric current from a welding power supply to be transferred from the body to the electrode. The body, in part of the length of the bore between an inlet end and an outlet end, has at least one region (herein referred to as a primary contact region) at which the body is adapted to enable primary electrical contact with the electrode, and along a remainder part of the length of the bore, the body is adapted such that any secondary contact between the body and the electrode along the remainder part does not substantially short circuit the primary electrical contact in the primary contact region of the bore.

Abstract: An arc-welding contact tip to be provided to a welding torch for establishing an electric connection with a consumable electrode fed to a welding zone through the contact tip during welding operations is disclosed. The contact tip includes a housing to be secured to the welding torch and defining an elongated interior passage through which the consumable electrode is to be fed to the welding zone while the welding operations are being performed. At least a portion of a peripheral surface defining the interior passage is provided with an electrically conductive metal alloy comprising copper and tungsten. Further, the metal alloy includes about 50% by weight to about 90% by weight tungsten.

Abstract: A contact tip for a welding gun includes an elongate body having a first end, a second end, and a first opening extending longitudinally between the first end and the second end. The elongate body has an outer surface and an inner surface. The elongate body has a second opening extending radially through a side portion of the elongate body between the outer surface and the inner surface. At least a portion of the second opening is configured to support a contact element. A contact element is configured to be supported within at least a portion of the second opening of the elongate body and extend at least partially into the first opening of the elongate body. A retention member is configured to couple the contact element with the elongate body.

Abstract: A contact tip for a welding gun having a central passage for a welding wire moving in a given direction toward a workpiece and receiving a welding signal by contact of the wire with the tip. The passage has an innermost end, an outermost exit end and a length of at least 1.5 inches and an opening in the contact tip intersects the passage so a pressure block slidably mounted in the opening is biased toward the wire by a spring around the contact tip urging the block against the wire. This tip is dimensioned and constructed to perform pulse welding by a relatively ductile aluminum wire.

Abstract: Locking engagement connections between various components of a welding device can include tapered features having varied thread patterns and/or varied angles to ensure that the components remain tight during service. For example, locking engagement connections can be incorporated between a nozzle and a retaining head, a retaining head and a gooseneck, and/or a contact tip and a retaining head.

Abstract: The invention relates to a welding current nozzle material used in the welding current nozzle for feeding filler material in MIG-type welding. The material used in the welding current nozzle according to the invention is a copper-based alloy where silver is alloyed.

Abstract: Contact nozzle 1 for electric arc welding with continuous welding wire 30 flowed through by welding current, which nozzle 1 can be connected to a welding torch and comprises an electrically conductive contact tube 10 with a longitudinal through-hole 4,5,6 intended for passage of the welding wire 30 during welding from an inlet end 2 to an outlet end 3 in said longitudinal hole 4,5,6, and also comprises a spring element 20 intended to apply a force to the welding wire in a direction essentially transverse to the feed direction of the wire so as to press the welding wire against the inside of the contact tube. It is characteristic that the spring element has been mounted from the inlet end in the first portion of length of the longitudinal hole, which portion of length 4 has a greater cross-sectional area than a second portion of length 5. There are also claims for an associated spring element 20 and a welding torch with a contact nozzle as above mounted.

Abstract: A contact provided in a welding tip of an arc welding apparatus includes a tip body adapted to be mounted to a welding torch body and a tip end member formed integrally therewith. The tip end member is divided into two parts, i.e., first and second halves by means of a slit formed along the axis of the tip end member, and the first half having the predetermined rigidity is movable around a connection between itself and the tip body. A spring member fitted on the tip end member applies a spring force thereto, whereby the contact has improved durability.

Abstract: Electrode and nozzle that seat within a retaining member and in two different seating locations relative to retaining member. The electrode and nozzle each include an interwoven-double-start thread having two thread cuts, which start 180 degrees from one another as measured around the circumference of the electrode or nozzle. Further, the electrode, nozzle, and retaining member include mating frustum surfaces, which are configured and dimensioned so that the electrode and nozzle seat within the retaining member with less than one turn of the electrode and nozzle relative to the retaining member. Therefore, the electrode and nozzle may be quickly inserted in, and removed from, the retaining member.

Abstract: A welding contact tip and diffuser assembly for use in a welding apparatus. The assembly includes an electrically conductive contact tip having a tapered exterior surface, a diffuser having a cavity with a tapered interior surface, and a releasable connection for holding the contact tip in the diffuser. The connection includes at least one detent element in either the diffuser or the contact tip, at least one recess forming a ramp in the other of the diffuser or contact tip, and at least one spring. The spring biases the detent element into the recess and against the ramp to generate an axial force against the ramp. The axial force tends to urge the tapered surfaces of the contact tip and diffuser into contact with one another.

Abstract: A method of forming a body by deposition of a weld material comprises providing a welding head (12), providing a foundation (52) upon which the body is to be formed. A weld material is supplied from a supply (22). The welding head (12) and the foundation (52) are connected to a supply of electricity to form an arc between the welding head (12) and the foundation (52) to melt the material. A raised member (74) is provided on the foundation (52). The method further includes manipulating the foundation (52) and the welding head (12) relative to each other to deposit the material on the raised member (74) and form the body.

Abstract: A MIG torch includes a contact tube and an auxiliary electrode made from carbon, which is electrically connected to the contact tube. In a start phase, a primary welding arc is started between an MIG wire and a workpiece, with stationary wire. The primary arc melts a small portion of the MIG wire, but then reaches the auxiliary electrode, and keeps on burning there stationary, wherein the workpiece does melt but not the MIG wire. When a welding pool is sufficiently large, the wire feed is started.

Abstract: A torch head having a base section, a tip section and three or more radial rods connected between the base section and the tip section. The radial rods form a generally circular inner chamber which inner chamber includes an electrode. One or more of the radial rods has an inner passageway to convey one or more shielding gasses and/or one or more cooling fluids from the base section to the tip section of the torch head. The cooling fluid cools at least a portion of the torch head. The shielding gas is directed about the electrode and onto the weld metal to improve the quality of the weld bead. One or more of the radial rods function as support structures to enhance the strength and the rigidity of the torch head. The tip section of the torch head is designed to direct the one or more shielding gas in a desired profile about the electrode and onto the weld metal. The tip section includes an electrical contact that form an electrical connection with the electrode as the electrode passes through the tip section.

Abstract: A welding torch (2) for use in gas metal arc welding, including a neck portion (4), a diffuser (6) at a first end (8) of the neck portion (4), a contact tip (10) which extends from the diffuser (6), and connector means (12) which is at a second end (14) of the neck portion (4) and which is for connecting the neck portion (4) to a power cable assembly; the neck portion (4) including an electrical conductor (16) and a longitudinally extending passageway (18); electrical current transfer from the electrical conductor (16) to the contact tip (10) being effected using first and second longitudinally separated contact areas (22, 24) on the contact tip (10); and the welding torch (2) including a gas chamber (30) which is positioned longitudinally between the two contact areas (22, 24) and radially between the contact tip (10) and the diffuser (6).

Abstract: According to one aspect of the present technique a novel ceramic contact tip extension is featured. The ceramic extension may comprise a zirconium-based material. According to another aspect of the present invention, a novel wire-feed welding system is featured. The welding system may feature an electrical power source, a wire-feeder having a wire electrically coupleable to the electric power source, and a welding implement adapted to receive a tubular metal wire from the wire-feeder. The welding implement has a contact tip and a contact tip extension. According to yet another aspect of the present technique, a method for protecting a contact tip is feature. The method comprises thermally insulating the contact tip.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: A welding gun adapted to secure a contact tip within the welding gun without threading the contact tip and without the use of tools. The contact tip may be adapted to abut a surface of a first member disposed within the welding gun. The surface may be a surface of a gas diffuser. The surface may be adapted to abut the contact tip. The contact tip also may be adapted for abutment with a second member to urge the contact tip toward the first member. The second member may be a portion of a nozzle adapted to abut the contact tip to urge the contact tip toward the surface of the first member. A method of assembling a welding gun also is provided. The method may comprise disposing a contact tip between a first and a second member and capturing the contact tip between the first and second members.

Abstract: A MIG welding gun contact tip has a cylindrical section with a predetermined outer diameter adjacent one end, and frusto-conical surface adjacent the other end. Threads are rolled from the cylindrical section outer diameter between the cylindrical section and the frusto-conical surface. The threads major diameter is larger than the cylindrical section outer diameter, and the threads minor diameter is less than the cylindrical section outer diameter. In a preferred embodiment, the cylindrical section outer diameter is approximately 0.350 inches, the threads have a major diameter of approximately 0.375 inches, and the threads are stub acme threads with a pitch of 14 threads per inch. The contact tip is assembled to a diffuser having mating threads and a frusto-conical surface that engages the contact tip frusto-conical surface when the contact tip has been turned a single turn into the diffuser.

Abstract: An arc welding system using a wire to produce an arc. The arc welding system comprising a welding handle. A tip being disposed in the welding handle to direct wire through the welding handle. The tip having a passage through the tip to receive the wire. The tip having an end portion adapted to be in facing relationship with a target material during welding. The passage having an outer surface layer of electroless nickel. The end portion having an outer surface layer of electrolytic nickel.

Abstract: The invention relates to a burner head (9) of an electric arc welding or cutting head, with preferably a melting wire electrode, having a contact nozzle (1) and a spring chuck (2) for releasably holding the contact nozzle (1) on the burner head (9). Both of the contact nozzle and the spring chuck (2) have corresponding means to bring about positive locking between the contact nozzle (1) and the spring chuck in the contact nozzle (1) that is supported on the burner head (9).

Abstract: A welding contact tip and diffuser assembly for use in a welding apparatus. The assembly includes an electrically conductive contact tip having a tapered exterior surface, a diffuser having a cavity with a tapered interior surface, and a releasable connection for holding the contact tip in the diffuser. The connection includes at least one detent element in either the diffuser or the contact tip, at least one recess forming a ramp in the other of the diffuser or contact tip, and at least one spring. The spring biases the detent element into the recess and against the ramp to generate an axial force against the ramp. The axial force tends to urge the tapered surfaces of the contact tip and diffuser into contact with one another.

Abstract: The shape of each electrical supply die for contact-supplying electricity to a wire electrode is changed to a cylindrical shape, and grooves are provided in its outer surface in parallel to the traveling direction of the wire, wherein upper electric supply is effected by contact-supplying of electricity at a projecting surface formed between adjacent ones of the grooves, while lower electric supply is effected by pressure contact-supplying of electricity by causing a concave surface to contact the groove.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: A current path for a mig welding gun assures a reliable and stable interface between a welding gun and a weld wire. In one embodiment, the current path is through a conductive insert that fits in the welding gun diffuser. Fingers of the insert resiliently contact the weld wire and thereby provide stable paths for welding power from the gun to the weld wire. In another embodiment, a contact tip assembly comprises a contact tip having resilient fingers in electrical contact with a body. An inner frusto-conical surface of a sleeve is urged against concentric frusto-conical outer surfaces of the fingers to bias the fingers radially inwardly against the weld wire. An insulative liner in the contact tip guides the weld wire between the fingers. A shield surrounds the contact tip and the sleeve. In a further embodiment, a single finger is pivotally connected to the contact tip. A spring biases a finger end against the weld wire.

Abstract: An arc welding system using a wire to produce an arc. The arc welding system comprising a welding handle. A tip being disposed in the welding handle to direct wire through the welding handle. The tip having a passage through the tip to receive the wire. The tip having an end portion adapted to be in facing relationship with a target material during welding. The passage having an outer surface layer of electroless nickel. The end portion having an outer surface layer of electrolytic nickel.

Abstract: A welding torch (2) for use in gas metal arc welding, comprising a neck portion (4), a diffuser (6) at a first end (8) of the neck portion (4), a contact tip (10) which extends from the diffuser (6), and connector means (12) which is at a second end (14) of the neck portion (4) and which is for connecting the neck portion (4) to a power cable assembly; the neck portion (4) comprising an electrical conductor (16) and a longitudinally extending passageway (18); electrical current transfer from the electrical conductor (16) to the contact tip (10) being effected using first and second longitudinally separated contact areas (22, 24) on the contact tip (10); and the welding torch (2) including a gas chamber (30) which is positioned longitudinally between the two contact areas (22, 24) and radially between the contact tip (10) and the diffuser (6).

Abstract: A MIG welding gun has a diffuser with an external thread and a frusto-conical back ramp. A nozzle assembly includes an insert with a back ramp and a thread that mates with the diffuser thread. The threads of the diffuser and insert have respective ramps that mate. A single turn of the nozzle assembly on the diffuser causes simultaneous engagement of the insert and diffuser back ramps and of the insert and diffuser thread ramps. Such engagement centers the nozzle to be concentric with the diffuser and also produces a wedging action that retains the nozzle assembly on the diffuser until a relatively substantial reverse torque is applied to the nozzle assembly. The nozzle front end has a narrow annulus, which reduces the amount of radiant heat from the welding arc that reaches the nozzle.

Abstract: A contact provided in a welding tip of an arc welding apparatus includes a tip body adapted to be mounted to a welding torch body and a tip end member formed integrally therewith. The tip end member is divided into two parts, i.e., first and second halves by means of a slit formed along the axis of the tip end member, and the first half having the predetermined rigidity is movable around a connection between itself and the tip body. A spring member fitted on the tip end member applies a spring force thereto, whereby the contact has improved durability.

Abstract: The invention relates to a stream nozzle (13) for an inert gas welding torch (B). The inventive nozzle is provided with a coating (S) that adheres to at least a part of the surface of said nozzle in a material fit and consists of silver, especially galvanically mounted contact silver.

Abstract: A torch head having a base section, a tip section and three or more radial rods connected between the base section and the tip section. The radial rods form a generally circular inner chamber which inner chamber includes an electrode. One or more of the radial rods has an inner passageway to convey one or more shielding gasses and/or one or more cooling fluids from the base section to the tip section of the torch head. The cooling fluid cools at least a portion of the torch head. The shielding gas is directed about the electrode and onto the weld metal to improve the quality of the weld bead. One or more of the radial rods function as support structures to enhance the strength and the rigidity of the torch head. The tip section of the torch head is designed to direct the one or more shielding gas in a desired profile about the electrode and onto the weld metal. The tip section includes an electrical contact that form an electrical connection with the electrode as the electrode passes through the tip section.

Abstract: A MIG welding gun contact tip has a cylindrical section with a predetermined outer diameter adjacent one end, and a frusto-conical surface adjacent the other end. Threads are rolled from the cylindrical section outer diameter between the cylindrical section and the frusto-conical surface. The threads major diameter is larger than the cylindrical section outer diameter, and the threads minor diameter is less than the cylindrical section outer diameter. In a preferred embodiment, the cylindrical section outer diameter is approximately 0.350 inches, the threads have a major diameter of approximately 0.375 inches, and the threads are stub acme threads with a pitch of 14 threads per inch. The contact tip is assembled to a diffuser having mating threads and a frusto-conical surface that engages the contact tip frusto-conical surface when the contact tip has been turned a single turn into the diffuser.

Abstract: A MIG welding gun has a diffuser with an external thread and a frusto-conical back ramp. A nozzle assembly includes an insert with a back ramp and a thread that mates with the diffuser thread. The threads of the diffuser and insert have respective ramps that mate. A single turn of the nozzle assembly on the diffuser causes simultaneous engagement of the insert and diffuser back ramps and of the insert and diffuser thread ramps. Such engagement centers the nozzle to be concentric with the diffuser and also produces a wedging action that retains the nozzle assembly on the diffuser until a relatively substantial reverse torque is applied to the nozzle assembly. The nozzle front end has a narrow annulus, which reduces the amount of radiant heat from the welding arc that reaches the nozzle.

Abstract: The invention relates to a contact tip for a welding or cutting torch which includes at least one internal opening for guiding and engaging at least one welding electrode, wherein the internal opening is produced by deep drilling in a bar-shaped semi-finished product, such as a solid material. The use of drawn semi-finished products can thus be eliminated, thereby widening the range of material selection and reducing the cost of the semi-finished product.

Abstract: A contact tube for supplying current in the case of a welding torch, having a tube body which contains a coaxial passage opening for a welding wire, the tube body containing a receiving opening coaxial to the passage opening, into which receiving opening at least one current transmission sleeve is inserted which consists of a material particularly suitable for transmitting current to the welding wire and which contains a coaxial passage which forms an axial section of the passage opening. Additionally, at least one guiding sleeve is inserted into the receiving opening, which guiding sleeve consists of a material particularly suitable for guiding the welding wire and which contains a coaxial passage which also forms an axial section of the passage opening.

Abstract: A welding system and method of use which allows a single welding operator to perform quick, easy and high quality vertical welds. The welding system comprises a welding fixture with a pair opposing, positionally adjustable welding shoes, and lock screws for attaching to a workpiece such as an I-beam. The welding fixture is located adjacent the end of an articulating boom, and a welding torch and oscillator are included on the welding fixture. A rotary straight wire feeder removes the cant and helix from welding wire as it is fed to the welding torch. The welding torch prevents welding wire from fusing to a guide tube in a manner which would interrupt a welding operation. The invention includes a distributed welding control system comprising a plurality of controller modules interfaced with a common bus. The control system allows a welding operator to program automated welding cycles for various welding operations.

Abstract: A welding gun contact tip which seats within a retaining member and in two different seating locations relative to the contact member. The contact tip includes an interwoven-double-start thread having two thread cuts which start 180 degrees from one another as measured around the circumference of the contact tip. Additionally, the retaining member includes an interwoven-double-start thread having two thread cuts which start 180 degrees from one another as measured around the circumference of the contact tip. Because of the configuration of the interwoven-double-start threads, the two seating locations of the contact tip are 180 degrees apart thereby enabling the contact tip to be used twice as long as a conventional contact tip which includes a single cut thread. Further, the contact tip and retaining member include mating frustum surfaces which are configured and dimensioned so that the contact tip seats within the retaining member with less than one turn of the contact tip relative to the retaining member.

Abstract: In an electric arc welder for creating an arc welding process between a consumable electrode advancing through a contact tip and a workpiece, the welder including a power supply to create an arc current and arc voltage and having a first lead connected to the contact tip and a second lead connected to the workpiece, the improvement comprising dividing the contact tip into an upper tip section and a lower tip section with an insulator electrically isolating the sections, a first switch selectively shiftable to a conductive state connecting one of the power supply leads to said upper tip section, a second switch selectively shiftable to a conductive state connecting the one lead to the lower tip section and a switch operating network creating a first switch signal to shift the first switch to its conductive state and/or a second switch signal to shift the second switch to its conductive state to control the effective CTWD of the arc welding process.

Abstract: A mig welding gun handle is in two sections that are offset from each other by an angle of approximately 20 degrees. The offset handle makes the gun exceptionally comfortable for an operator to maneuver when welding various workpieces. A non-right angle gear set in which the pinion axial centerline intersects the gear axis of rotation at an angle of approximately 70 degrees makes the offset handle possible. The gun further comprises a gas seal that blocks atmospheric air in the weld wire liner from reaching the welding arc. The gas seal comprises a passage that bleeds inert gas to the interior of the liner. The relatively high pressure of the inert gas in the liner interior blocks atmospheric air from flowing through the hole in the contact tip to the arc.