Electrode diameter sensing consumables are disclosed. An example shielded metal arc welding (SMAW) torch comprises: a handle; a clamp coupled to the handle configured to open and close to hold a SMAW electrode, the clamp comprising a pivot configured to rotate based on a degree of openness of the clamp; and a potentiometer coupled to the pivot such that an output of the potentiometer is representative of a degree of rotation of the pivot

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.

A contact device for a welding apparatus is disclosed. The contact device for feeding current to at least a first welding wire and a second welding wire. The contact device including first and second contact jaws. The first and second contact jaws including a slot formed therein to provide the first and second contact jaws with improved flexibility to individually and independently flex about the first and second welding wires to ensure proper contact is maintained between the contact jaws and the welding wire.

A contact device for a welding apparatus is disclosed. The contact device for feeding current to at least a first welding wire and a second welding wire. The contact device including first and second contact jaws. The first and second contact jaws including a slot formed therein to provide the first and second contact jaws with improved flexibility to individually and independently flex about the first and second welding wires to ensure proper contact is maintained between the contact jaws and the welding wire.

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.

In various embodiments, wire composed at least partially of arc-melted refractory metal material is utilized to fabricate three-dimensional parts by additive manufacturing.

The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch, and a sensor, in which the sensor is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor. The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

The present disclosure provides a welding system capable of detecting a size of a welding material and automatically implementing appropriate arc starting parameters. The welding system includes a welder, a welding torch, and a sensor, in which the sensor is configured to detect the size of the welding material, directly or indirectly. The welder is automatically configured to produce an arc having the arc starting parameters determined from the size of the welding material detected by the sensor. The present disclosure decreases operational error by automatically changing arc starting parameters and/or welding parameters based upon a change in welding material size, rather than requiring an operator to manually change the arc starting parameters and/or welding parameters.

In various embodiments, three-dimensional layered metallic parts are substantially free of gaps between successive layers, are substantially free of cracks, and have densities no less than 97% of the theoretical density of the metallic material.