An arc welding system providing improved molten metal droplet transfer. The system includes a welding power source having a welding power supply, a welding waveform generator, and a controller. Two fluxed cored welding wire electrodes are connected to the power source and are powered by the same welding output voltage and current produced by the power source. A feedback circuit is connected to the power source to provide an adaptive response to maintain an average welding output voltage. The controller controls the waveform generator and the power supply to superimpose welding current pulses onto a welding waveform of a CV flux cored arc welding process, that uses CO.sub.2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process. The current pulses are superimposed in time to form molten metal droplets between ends of the two electrodes during the modified welding process.

Systems and methods to control pulse welding are disclosed. An example welding-type system includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to control the power conversion circuitry to output the welding-type power in a plurality of pulse cycles, each pulse cycle including background, ramp up, peak, and ramp down phases. Controlling the power conversion circuitry involves: during the background phase, controlling the power conversion circuitry in a voltage-controlled mode using a background voltage as a target voltage; during the ramp up phase, controlling the power conversion circuitry by changing the target voltage to a peak voltage; during the peak phase, controlling the power conversion circuitry using the peak voltage as the target voltage; and during the ramp down phase, controlling the power conversion circuitry by changing the target voltage to the background voltage.

A real-time virtual reality welding system including a programmable processor-based subsystem, a spatial tracker operatively connected to the programmable processor-based subsystem, at least one mock welding tool capable of being spatially tracked by the spatial tracker, and at least one display device operatively connected to the programmable processor-based subsystem. The system is capable of simulating, in virtual reality space, a weld puddle having real-time molten metal fluidity and heat dissipation characteristics. The system is further capable of importing data into the virtual reality welding system and analyzing the data to characterize a student welder's progress and to provide training.

Advanced device for the welding training based on simulation with Augmented reality and with remote updates that allows the simulation of: all the industrial welding types—s electrode stick (SMAW), MIG/MAG (GMAW, FCAW) and TIG (GTAW)—; all the materials; all the joint types and, also all the welding positions (1Fa 4F, 1G a 6G, 6GR, etc.). It offers an accurate simulation of a real welding equipment thanks to the use of the Augmented Reality technology, which allows the interaction between different elements in several layers. All this is implemented by a monitoring and student evaluating system that allows the teacher to control remotely what is happening in the classroom in real time and without the necessity of being physically present in the training.

A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

A portable advanced process module system includes, for example, a welding power source, an portable advanced process module, and a wire feeder. The portable advanced process module and the wire feeder are separately enclosed in suitcase style enclosures with disconnectable power and communication means between the portable advanced process module and the wire feeder. The processing unit includes power electronics to enable advanced weld processes that can be delivered to the wire feeder and a welding work piece. The portable advanced process module is powered by a DC bus that can be supplied by a welding power source. Connecting the portable advanced process module between the welding power source and the wire feeder enables advanced welding processes to be accomplished at great distances from the main welding power source. Separating the power electronics into the portable advanced process module and maintaining a standard suitcase wire feeder form factor keeps the welding equipment used in the working area envelope small, light, and portable.

An arc welding method includes the following steps. Pulse arc welding is performed with the welding wire being fed in a forward direction during a first period. Short-circuit transfer arc welding is performed with the welding wire being fed in the forward direction and the reverse direction during a second period. The first period and the second period are alternately switched. The switching of the first period to the second period is performed in a manner such that no transfer of a molten droplet of the welding wire occurs during the final pulse cycle of the first period.

An arc welding method includes the following steps. Pulse arc welding is performed with the welding wire being fed in a forward direction during a first period. Short-circuit transfer arc welding is performed with the welding wire being fed in the forward direction and the reverse direction during a second period. The first period and the second period are alternately switched. The switching of the first period to the second period is performed in a manner such that no transfer of a molten droplet of the welding wire occurs during the final pulse cycle of the first period.

An arc welding method is described where pulse arc welding is performed with a welding wire being fed in a forward direction during a first period and short-circuit transfer arc welding is performed with the welding wire being fed in the forward direction and a reverse direction during a second period. The arc welding method alternately switches between the first period and the second period, where the switching of the first period to the second period is performed during a peak period of the pulse arc welding.

An arc welding method is described where pulse arc welding is performed with a welding wire being fed in a forward direction during a first period and short-circuit transfer arc welding is performed with the welding wire being fed in the forward direction and a reverse direction during a second period. The arc welding method alternately switches between the first period and the second period, where the switching of the first period to the second period is performed during a peak period of the pulse arc welding.