Abstract: A MIG/MAG welding torch body includes a second channel, which is arranged coaxially to the central channel, and a further third channel, which is arranged coaxially to the second channel, wherein a connection is provided between the second channel and the third channel. The first channel has an orifice in the center of the receiving part, the second channel has an orifice on the lateral side of the receiving part, and the third channel has an orifice on the lateral side of the receiving part.

Abstract: In some aspects, contact members to connect plasma torch leads to plasma cutting systems can include: a base portion; a set of ports within the base portion that include: a coolant supply port to convey a liquid coolant from the cutting system to a plasma arc torch connected to the contact member by the torch lead, a coolant return port: i) to convey return liquid coolant from the torch to the cutting system, and ii) to convey an operational current from the cutting system to the torch, at least one gas supply port to convey processing gases to the torch, and an ohmic contact connector; and a connector to couple the base portion to the cutting system and connect each of the ports and electrical connectors to respective complementary connections of the cutting system upon coupling to the cutting system.

Abstract: A torch pole assembly including a torch pole having a top, a bottom, and a length between the top and bottom. An opening passes through the torch pole transverse to its length. A step comprises a pair of spaced apart sidewalls, each defining a sidewall opening situated on the common axis, and a floor spanning between the sidewalls and spaced apart from the sidewall openings. An axle occupies the common axis and passes through the pair of sidewall openings and the torch pole opening. The step is rotatable from a parallel position to a perpendicular position in which the floor is perpendicular to the length of the torch pole, the step floor defining a cutout proximate the collar that receives and contacts the collar when the step is in the perpendicular position thereby preventing the step from rotation beyond the perpendicular position.

Abstract: Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.

Abstract: A universal conduit assembly for a welding torch is provided that includes a conduit liner defining a proximal end portion and a distal end portion, a conduit tip secured to the proximal end portion of the conduit liner, and an interchangeable conduit stop removably secured to the conduit tip. The interchangeable conduit stop is adapted for connection to a specific OEM (Original Equipment Manufacturer) power connector.

Abstract: The invention relates to a plug part (21) for detachable connecting a torch neck (19) of a water-cooled welding torch (7) to a socket part (34) arranged on a hose package (20), having a cylindrical pipe element (22) with an axially running channel (23) for a welding wire (9) and a protective gas (5) and having at least two cooling channels (29, 30) for supplying and returning a cooling fluid, and a union nut (24) rotatably arranged on the pipe element (22), the union nut having an internal thread for connection to a mating external thread on the socket part (34), the invention further relating to such a socket part (34). In order to produce an optimal connection between the torch neck (19) and the hose package (20), a flange (25) having at least one receiving opening for receiving a pin-like element (36) of the socket part (34) is arranged on the pipe element (22) of the plug part (21) in order to fix at least one angular position of the torch neck (19).

Abstract: A jump liner for a push-pull MIG welding torch includes an elongated tubular body having front and back ends. The tubular body is made of a flexible plastic material. A front adapter is disposed at the front end of the tubular body. The front adapter is fittable in a retaining head of the torch. A back adapter is disposed at the back end of the tubular body. The back adapter is fittable in a gooseneck or body block of the welding torch. The front adapter provides sealing between the jump liner and the retaining head to prevent back flow leakage of shielding gas, and the front adapter prevents deformation of the tubular body at elevated temperatures. The back adapter provides sealing between the jump liner and the gooseneck or body block.

Abstract: A gas metal arc welding system that includes first and second welding torch assemblies arranged to operate in tandem. The first welding torch assembly further includes a rotable torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes an angled passage formed therethrough; a consumable wire electrode passing through the rotating torch body and exiting the contact tip through the offset exit hole; and a source of shielding gas. The second welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

Abstract: A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip, and a principal distance from the at least one aperture to the distal end face is varied to adjust the flow of the shield gas for improved cooling.

Abstract: The invention relates to a plug part (21) for detachable connecting a torch neck (19) of a water-cooled welding torch (7) to a socket part (34) arranged on a hose package (20), having a cylindrical pipe element (22) with an axially running channel (23) for a welding wire (9) and a protective gas (5) and having at least two cooling channels (29, 30) for supplying and returning a cooling fluid, and a union nut (24) rotatably arranged on the pipe element (22), the union nut having an internal thread for connection to a mating external thread on the socket part (34), the invention further relating to such a socket part (34). In order to produce an optimal connection between the torch neck (19) and the hose package (20), a flange (25) having at least one receiving opening for receiving a pin-like element (36) of the socket part (34) is arranged on the pipe element (22) of the plug part (21) in order to fix at least one angular position of the torch neck (19).

Abstract: Systems and methods for improved liquid cooling of a tungsten inert gas (TIG) welding torch are provided. The improved welding torch may feature conduits for conveying coolant from a cooling system to a collar, which holds a tungsten electrode of the welding torch, and back. A coolant return conduit may be disposed in a coolant supply conduit to improve thermal insulation of an outer surface of the welding torch. Some embodiments may feature a helical channel formed in the collar for conveying coolant around the electrode multiple times before returning the coolant through the return conduit.

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 welding implement and a method of extracting heat from a welding implement are disclosed. The welding implement includes one or more heat pipes which transfer thermal energy away from the torch head. A fluid, such as a shielding gas, may then convectively transfer the thermal energy away from the welding implement. The present invention thus provides a handheld welding implement that is compact, such that it can be used in confined spaces, and operated for longer periods of time, since the improved heat dissipation helps to maintain the welding implement at a temperature that an operator may hold.

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: A cooled welding torch (1) having a cooling circuit, which cooling circuit extends via a nozzle fitting receiver (3) into a gas nozzle (9), and the gas nozzle (9) is attachable to the welding torch (1) by a defined turn, wherein the cooling circuit is routed through a redirecting element (5), which redirecting element (5) is positioned above the nozzle fitting receiver (3) and may be turned together with the gas nozzle (9), wherein a path of the cooling circuit is switchable by the position of the gas nozzle (9).

Abstract: A removable cooling collar is provided for cooling the nozzle of a welding nozzle. This collar includes first and second parts in fluid communication with a chamber that extends circumferentially within a hollow structure. Cooling fluid circulating through the chamber facilitates dissipation and/or extraction of heat in the nozzle, in turn reducing the likelihood of weld splatter adhesion on the nozzle.

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 securement member for securing a contact tip to a welding torch assembly is provided. A channel extends axially therethrough and has an internal shoulder that extends into this channel. This internal shoulder abuts against a shoulder on the contact tip, capturing the contact tip between the shoulder and a seating surface on the diffuser and securing the contact tip in the torch assembly. The contact tip is securely seated without threading engagement, facilitating quick release and installation. The exemplary securement member couples to the diffuser such that the egress of fluid from the diffuser is blocked when used for gasless welding. This blocking allows a user to leave the diffuser secured to the welding torch when a gasless electrode is in use.

Abstract: A gas-cooled welding gun for an arc welding device, comprising an electrically conductive current contact tube disposed concentrically within an electrically conductive outer tube and separated therefrom by an intermediate space. The current contact tube includes a wire guiding channel for a welding wire. A plurality of spacers is disposed at intervals in the intermediate space between the current contact tube and outer tube,. electrically insulating these components from each other. A shielding gas is provided in the intermediate space to cool the system and openings in the spacers allow the gas to flow therethrough. Structures are provided on the current contact tube which increase the overall surface area thereof. Regions of the surface of the current contact tube not covered by spacers are exposed toward the intermediate space and therefore to the shielding gas.

Abstract: The invention provides a compact and economical welding control system having an integrated power section. To this end, a switching module is provided for the power section of a welding control system. The switching module has a switching device, at least one cooling body, a current supply and an insulating element which provides a potential-free coolant arrangement. The invention is advantageous in that the potential-free coolant arrangement allows the coolant bodies to be shortened so that less space is required inside the control system and the control system can therefore have a more compact structure. The invention enables even the requirements in terms of the coolant bodies to be reduced, allowing the use of cost-effective cooling tubes or even cooling pipes that are directly connected to the cooling body.

Abstract: Systems and methods for improved liquid cooling of a tungsten inert gas (TIG) welding torch are provided. The improved welding torch may feature conduits for conveying coolant from a cooling system to a collar, which holds a tungsten electrode of the welding torch, and back. A coolant return conduit may be disposed in a coolant supply conduit to improve thermal insulation of an outer surface of the welding torch. Some embodiments may feature a helical channel formed in the collar for conveying coolant around the electrode multiple times before returning the coolant through the return conduit.

Abstract: A gas metal arc welding system that includes first and second welding torch assemblies arranged to operate in tandem. The first welding torch assembly further includes a rotable torch body; a contact tip connected to one end of the rotatable torch body, wherein the contact tip further includes an angled passage formed therethrough; a consumable wire electrode passing through the rotating torch body and exiting the contact tip through the offset exit hole; and a source of shielding gas. The second welding torch assembly further includes a non-rotatable torch body; a contact tip connected to one end of the non-rotatable torch body; a consumable wire electrode passing through the non-rotatable torch body and exiting through the contact tip; and a source of shielding gas.

Abstract: The invention provides a welding arrangement designed to respond to the need of an improved welding system that aids in supplying filler material to a weld location. Provided is a welding system including a welding gun and a welding wire feed directly coupled to the welding gun. The welding gun includes a filler material housing, a filler material positioning extension, and a manual advancement device configured to advance a filler material through the welding wire feed. Further provided is a method of operating a welding gun. The method includes passing a current between an electrode and a work piece at a weld location, and advancing a filler material toward the weld location via a channel of a positioning extension in response to engagement of a manual advancement device.

Abstract: A torch and a welding system having a pair of gas paths are disclosed. The torch includes a wire feed assembly and is connectable to a welding-type power source and a source of shielding gas. A power signal suitable for welding applications and a shielding gas are communicated through the torch. The shielding gas is communicated through the torch by a pair of gas passages.

Abstract: A welding implement and a method of extracting heat from a welding implement are disclosed. The welding implement includes one or more heat pipes which transfer thermal energy away from the torch head. A fluid, such as a shielding gas, may then convectively transfer the thermal energy away from the welding implement. The present invention thus provides a handheld welding implement that is compact, such that it can be used in confined spaces, and operated for longer periods of time, since the improved heat dissipation helps to maintain the welding implement at a temperature that an operator may hold.

Abstract: A heat pipe cooling system adapted for exemplary use with a gas metal arc welding torch, includes a container enclosing a capillary structure and quantity of working fluid, and functions to accelerate the dissipation of heat energy from a heated zone generated by the torch through the vaporization and condensation of the fluid and the capillary action of the structure.

Abstract: A welding implement includes a torch having a flexible torch head. The torch head is operable to conduct electricity to a welding electrode disposed within the torch head. The welding implement may include a gas supply tube and a coiled wire spring operable to flexibly couple the gas supply tube to the torch head. The welding implement may include a torch that directs a fluid to flow axially through a spring coupled the torch head. The welding implement may also include a torch including a torch head and a tripod support system to flexibly support the torch head. Each of the legs of the tripod support system may include a spring.

Abstract: A cooling system is disclosed that is designed to inhibit coolant flow to a welding-type component if connection of the welding-type component to a coolant outlet is not deemed present.

Abstract: A cooling system connected to provide coolant to a welding-type component automatically circulates coolant through the welding component upon activation of the welding component. A controller is configured to regulate the cooling system such that upon activation of the welding-type component coolant is caused to at least flow through the welding-type component, and circulate after deactivation of the welding torch until a temperature of the coolant falls below a certain value or a specified time period has expired. The cooling system is constructed to be integrally disposed within a power source housing.

Abstract: A welding torch having a flange portion to be coupled to a wrist of a robot. A shock sensor is attached to the flange portion. A nozzle is attached to the shock sensor. The welding torch includes a wire feeding pipe socket arranged at a center of the flange portion. A cooling pipe socket is arranged at a position offset from a central portion of the flange portion. A cooling hose for feeding cooling water from the flange portion to the nozzle is provided while bypassing the shock sensor.

Abstract: A highly durable cable hose assembly for connecting a welding machine to the conductor tube portion of a pressurized air cooled welding torch includes a cable hose, a rear connector portion for connecting to a welding machine and a front connector portion for connecting to the conductor tube. The cable hose portion includes a gas hose for passage of inert gas, a plurality of cooling air tubes for conducting cooling air, conductive stranding for conveying electrical current for arc welding and a flexible outer hose jacket for enclosing the gas hose, the plurality of cooling air tubes and the conductive stranding in a generally tightly bundled fashion.

Abstract: A motor-driven welding gun has a servomotor for displacing a movable electrode tip toward and away from a fixed electrode tip. The servomotor has a motor housing with a copper pipe which is inserted therein when the motor housing is cast. The copper pipe provides a coolant passage in the motor housing for supplying a coolant therethrough. When the coolant passage is supplied with the coolant, the motor housing is forcibly cooled, reducing the amount of heat generated by the servomotor.

Abstract: An in-line welding gun includes a mounting block, a wire feed mechanism and a torch barrel. A motor is positioned behind the mounting block along a longitudinal axis of the gun. The torch barrel curves away from the longitudinal axis. The motor and the torch barrel are surrounded by a substantially rigid shell comprising a tubular portion and a torch portion.

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: A liquid-cooled welding device comprising a torch head body having a helical cooling fin extending along a length of the torch head body. A sleeve may be disposed around the torch head body to define a flow channel over the torch head body. The sleeve may have a liquid inlet and a liquid outlet to enable liquid to flow into and out of the flow channel. The liquid outlet may be located adjacent to the liquid inlet. The liquid-cooled welding device may have a baffle disposed within the sleeve between the liquid inlet and the liquid outlet to direct liquid to flow along the length of the torch head body to enable the helical cooling fin transfer heat to the liquid.

Abstract: A welding system having a welding gun with a handle. The handle is adapted to cool the interior of the handle with a flow of air. The handle may be adapted with a plurality of ventilation holes to enable air to pass through the handle. The handle may have a plurality of ribs disposed along the interior of the handle to direct air flow around a conductive member disposed therein. The ribs may be adapted to direct the air to flow radially and/or longitudinally around the interior of the handle.

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: A welding system having a welding gun with a handle. The handle is adapted to cool the interior of the handle with a flow of air. The handle may be adapted with a plurality of ventilation holes to enable air to pass through the handle. The handle may have a plurality of ribs disposed along the interior of the handle to direct air flow around a conductive member disposed therein. The ribs may be adapted to direct the air to flow radially and/or longitudinally around the interior of the handle.

Abstract: An improved welding apparatus, for use with a MIG apparatus, or a tungsten rod in a TIG apparatus. A nozzle housing, having an outer shroud, defines an airspace, which receives an injection of water vapor mist. The water vapor mist, when directed into the airspace in the nozzle housing, contacts the heated nozzle housing surface, and is then able to absorb the heat energy from the nozzle housing surface. When the water vapor mist absorbs heat energy, it undergoes a phase change from atomized water into steam. The steam is allowed to exit out of the rear portion of the rear of the nozzle assembly. The phase change of water to steam provides a significant heat transfer, due to the latent heat energy absorption capability of the water that is required to convert it from a liquid state to a gaseous state. This cooling apparatus, and method of cooling, both utilize a minimal amount of water usage, and also dramatically extends the usable life of the welding apparatus.

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 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: An electrospark alloying apparatus includes a main body member, a collet coupled to the main body member, and a heat sink adjacent the collet. The collet is adapted to receive and hold a consumable electrode. The apparatus can also include a drive for rotating the electrode. Further, the apparatus can include an inert gas supply and a discharge opening in the main body member for facilitating lamellar gas flow of insert gas from the inert gas supply around the electrode. A method of electrospark alloying includes electrospark alloying a workpiece with a consumable electrode and cooling the electrode during the electrospark welding.

Abstract: A nozzle for a welding gun for shielded arc welding comprises a cooling fluid section and a gas nozzle assembly structured to optimize the cooling and thermal protection of the component parts of the gas nozzle assembly from melting or other damage resulting from exposure to extremely high temperatures in connection with performing a shielded arc welding process in a confined space having limited heat dissipating capability. The cooling fluid section has inlet and outlet passageway portions including changes in heat transfer surface areas, and a heat sink and insulating section is provided between the cooling fluid section and the gas nozzle assembly. The gas nozzle assembly includes a sleeve of thermosetting silicone material to optimize transfer of heat from the gas diffuser and shroud components thereof to the heat sink and insulating section.