A wire guide conduit is constructed from a coiled wire having an oval or elliptical cross-sectional shape. The wire is subjected to a directed energy beam to locally heat portions of the wire to create discrete areas of increased hardness in the surface of the wire. The wire is coiled to present the locally hardened regions on an inside passageway of the conduit. The wire guide conduit may be used in additional applications such as a control wire for an actuation system.

A wire feeding device configured to feed welding wire from a wire feeding source to a welding torch is provided with: an intermediate wire feeding source that is disposed between the wire feeding source and the welding torch and is configured to temporarily store the welding wire fed from the wire feeding source and to feed the stored welding wire to the welding torch; a first feeding part that feeds the welding wire at the wire feeding source to the intermediate wire feeding source; a second feeding part that feeds the welding wire stored in the intermediate wire feeding source to the welding torch; and a feed control unit that controls speed of feeding the welding wire by each of the first feeding part and the second feeding part.

A wire feeding device configured to feed welding wire from a wire feeding source to a welding torch is provided with: an intermediate wire feeding source that is disposed between the wire feeding source and the welding torch and is configured to temporarily store the welding wire fed from the wire feeding source and to feed the stored welding wire to the welding torch; a first feeding part that feeds the welding wire at the wire feeding source to the intermediate wire feeding source; a second feeding part that feeds the welding wire stored in the intermediate wire feeding source to the welding torch; and a feed control unit that controls speed of feeding the welding wire by each of the first feeding part and the second feeding part.

A welding or additive manufacturing wire drive system includes a welding wire spool and first and second drive rolls. One or both of the drive rolls has a circumferential groove. The system includes a first welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove, and a second welding wire, drawn from the welding wire spool, and located between the drive rolls in the circumferential groove. The first welding wire contacts the second welding wire between the first drive roll and the second drive roll. The first welding wire further contacts a first sidewall portion of the circumferential groove, and the second welding wire further contacts a second sidewall portion of the circumferential groove. Both of the first welding wire and the second welding wire are radially offset from a central portion of the circumferential groove.

Systems, methods, and apparatuses of a welding system are disclosed and include a first stage of a scanning device for scanning weld parts to generate a three-dimensional (3D) profile of a weld target wherein the 3D profile captures matching imperfections of a meeting together of the set of weld parts when performing the weld operation; and the second stage of a monitoring device to monitor the weld operation and to generate a data of high-resolution measurements of the weld operation; wherein the first stage further includes the monitoring device determining a weld schedule based on the 3D profile, and to adjust the weld schedule while the weld operation progresses to adapt to predicted distortion based on the 3D profile and to sensed distortion; wherein the second stage further includes a plurality of sensors to sense a set of components associated with the weld operation to generate high-resolution data of measurements.

An example welding system includes: a welding power supply configured to convert input power to welding power; a wire feeder configured to feed welding wire to a welding torch; and control circuitry configured to: in response to an initiation of a welding process, control the wire feeder to feed the welding wire at a first rate while controlling the welding power supply to output the welding power to initiate a welding arc; in response to initiation of the welding arc, control the wire feeder to increase a feed rate of the wire feeder from the first rate to a second rate; and in response to determining that a temperature profile of a heated portion of the welding wire has stabilized, control the wire feeder to change the feed rate of the wire feeder from the second rate to a target wire feed speed.

Methods and apparatus to synergically control a welding-type output during a welding-type operation are disclosed. An example welding-type power supply includes a power conversion circuit configured to convert input power to welding-type power and to output the welding-type power to a welding-type torch; a communication circuit configured to receive a control signal from a remote control device during a welding-type operation; and a control circuit configured to synergically control a voltage of the welding-type power and a wire feed speed based on the control signal.

A welding torch system includes a diffuser assembly that includes a locking mechanism to receive a contact tip. Additionally, the welding torch system includes the contact tip, which includes locking elements configured to interact with the locking mechanism of the diffuser assembly to secure the contact tip within the diffuser assembly. Further, the contact tip is rotated within the diffuser assembly to securely align the locking elements with the locking mechanism.

In preparing a built-up object by depositing beads, in a step of dividing into the bead model, a trapezoidal bead model a cross section of which is a trapezoidal shape is applied to a position where the bead is formed in a portion not adjacent to an existing bead, and a parallelogram bead model a cross section of which is a parallelogram is applied to a position where the bead is formed adjacent to a bead that is already formed, in the parallelogram bead model opposite sides in the deposition direction of the bead being parallel to each other, and opposite sides in the bead arrangement direction being parallel to a side of another bead mode that is adjacent.

In preparing a built-up object by depositing beads, in a step of dividing into the bead model, a trapezoidal bead model a cross section of which is a trapezoidal shape is applied to a position where the bead is formed in a portion not adjacent to an existing bead, and a parallelogram bead model a cross section of which is a parallelogram is applied to a position where the bead is formed adjacent to a bead that is already formed, in the parallelogram bead model opposite sides in the deposition direction of the bead being parallel to each other, and opposite sides in the bead arrangement direction being parallel to a side of another bead mode that is adjacent.