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.

An example wire feeder includes: a frame; a receptacle configured to transfer welding-type current to a welding torch via a torch connector, and to position the torch connector to receive a wire electrode; one or more drive rolls configured to drive the wire electrode to the welding torch, the one or more drive rolls being electrically insulated from the frame, and wherein the wire electrode is electrically insulated from the frame; and a sensor configured to determine at least one of a voltage or an impedance between a first point electrically coupled to the wire electrode and a reference point.

An example wire feeder includes: a frame; a receptacle configured to transfer welding-type current to a welding torch via a torch connector, and to position the torch connector to receive a wire electrode; one or more drive rolls configured to drive the wire electrode to the welding torch, the one or more drive rolls being electrically insulated from the frame, and wherein the wire electrode is electrically insulated from the frame; and a sensor configured to determine at least one of a voltage or an impedance between a first point electrically coupled to the wire electrode and a reference point.

The invention relates to a welding head (1) comprising a heat-resistant electrode (2) for carrying out TIG welding operations on workpieces, in which the electrode (2) is movably mounted and can also be caused to move by a device (20). The electrode (2) preferably carries out either a rotating movement about the axis (A) thereof or an oscillating movement about said axis. During a preferably manual welding operation, undesired alloying-up is thus excluded during accidental contact between the electrode (2) and the workpiece to be welded. Moreover, repeated adhesion of liquefied welding filler material to the electrode (2) can be substantially prevented in the event that a welding filler material is supplied. With welding heads (1) which are cooled by means of a fluid circuit, said circuit, in cooperation with a turbine, can also be used to drive a rotating electrode (2). The movable electrode (2) can be connected to the voltage source thereof either via a sliding contact or via an electrically conducting liquid surrounding the electrode (2). The invention further relates to a method in which the welding head (1) according to the invention is used.

The invention relates to a welding head (1) comprising a heat-resistant electrode (2) for carrying out TIG welding operations on workpieces, in which the electrode (2) is movably mounted and can also be caused to move by a device (20). The electrode (2) preferably carries out either a rotating movement about the axis (A) thereof or an oscillating movement about said axis. During a preferably manual welding operation, undesired alloying-up is thus excluded during accidental contact between the electrode (2) and the workpiece to be welded. Moreover, repeated adhesion of liquefied welding filler material to the electrode (2) can be substantially prevented in the event that a welding filler material is supplied. With welding heads (1) which are cooled by means of a fluid circuit, said circuit, in cooperation with a turbine, can also be used to drive a rotating electrode (2). The movable electrode (2) can be connected to the voltage source thereof either via a sliding contact or via an electrically conducting liquid surrounding the electrode (2). The invention further relates to a method in which the welding head (1) according to the invention is used.

This invention relates to welding processes employing a TIG torch with a non-consumable electrode and a consumable filler rod with the end of the rod being progressively melted by an electric arc generated between the electrode end and the work piece to be welded transferring molten metal from the rod to the melt metal of the work piece (weld puddle) to form a weld joint. Providing a non-consumable arc isolation sleeve guard around the electrode allowing a pre-determined portion of the electrode to be exposed limiting arc variation and wandering.

This invention relates to welding processes employing a TIG torch with a non-consumable electrode and a consumable filler rod with the end of the rod being progressively melted by an electric arc generated between the electrode end and the work piece to be welded transferring molten metal from the rod to the melt metal of the work piece (weld puddle) to form a weld joint. Providing a non-consumable arc isolation sleeve guard around the electrode allowing a pre-determined portion of the electrode to be exposed limiting arc variation and wandering.

A system and method for wire-arc additive manufacturing to provide a wire-arc additive manufacturing device having a self-shielding system with a gantry and a computer numerical control type control system which enables precise infill patterns not normally obtainable with robotic control, whereby the additive manufacturing system includes a metal deposition device configured to deposit a metal material during an additive manufacturing process, whereby a controller may be operatively coupled to the metal deposition device to command the metal deposition device to deposit an infill pattern based on one or more stored patterns.

A system and method for wire-arc additive manufacturing to provide a wire-arc additive manufacturing device having a self-shielding system with a gantry and a computer numerical control type control system which enables precise infill patterns not normally obtainable with robotic control, whereby the additive manufacturing system includes a metal deposition device configured to deposit a metal material during an additive manufacturing process, whereby a controller may be operatively coupled to the metal deposition device to command the metal deposition device to deposit an infill pattern based on one or more stored patterns.

An example welding torch includes: a first contact tip configured to conduct welding current to a consumable electrode; a second contact tip configured to conduct preheating current to the consumable electrode; a cooling assembly configured to transfer heat from at least the first contact tip to coolant and to conduct the welding current through the cooling assembly; wherein the first contact tip and the cooling assembly are removable from the welding torch as a single unit.