In a method for scanning the surface of metallic workpieces, during scanning, a welding torch with a consumable welding wire is moved over and towards the workpiece surface, until contact of the welding wire with the workpiece is detected, and the welding wire is subsequently moved away from the workpiece. Before scanning, slag-removal is carried out to remove slag at the welding wire end, wherein the welding current is lowered to a minimum, and the welding wire is moved cyclically with a rapid recurrent forward/backward movement over a specified path length toward the workpiece, and by a smaller distance away from the workpiece, until a short circuit between the welding wire and the workpiece is detected, whereupon slag-removal is ended, and upon the detection of no short circuit, slag-removal is repeated, and upon the detection of several short circuits one after the other, slag-removal is ended.

Embodiments of welding systems and methods with coordinated dual power outputs supporting a same welding process or a same AC output process are disclosed. One embodiment of a welding system includes an engine and a generator operatively connected to the engine, where the engine is configured to drive the generator to produce electrical input power. The welding system also includes a power supply operatively connected to the generator and having at least one controller. The power supply is configured to convert the electrical input power to form two power outputs that are coordinated with each other, at least in time, via the controller to support a same welding process. The same welding process may be, for example, a hotwire welding process, a tandem metal inert gas (MIG) welding process, or an alternating current (AC) output process.

Embodiments of welding systems and methods with coordinated dual power outputs supporting a same welding process or a same AC output process are disclosed. One embodiment of a welding system includes an engine and a generator operatively connected to the engine, where the engine is configured to drive the generator to produce electrical input power. The welding system also includes a power supply operatively connected to the generator and having at least one controller. The power supply is configured to convert the electrical input power to form two power outputs that are coordinated with each other, at least in time, via the controller to support a same welding process. The same welding process may be, for example, a hotwire welding process, a tandem metal inert gas (MIG) welding process, or an alternating current (AC) output process.

An orientation and guide mechanism for a welding system includes a pair of opposed guide members. A weld wire having a non-round cross-section is fed through a guide passageway formed between the guide members, each of which have recessed channels that combine to define the guide passageway. The guide passageway has a non-round shape corresponding to the non-round shape of the wire. The orientation mechanism and the guide members thereof is adjustable relative to a welding device of the weld system, such that the orientation of the wire can be controlled and maintained by adjusting the orientation mechanism. The wide side of the wire may be adjusted to be presented to a radiant energy source, and/or the non-round wire may be adjusted relative to the desired weld seam.

A three-dimensional (3D) metal object manufacturing apparatus is configured to increase the oxidation of ejected melted metal drops for the formation of metal support structures during manufacture of a metal object with the apparatus. The oxidation can be increased by either increasing a distance between the ejector head and a platform supporting the metal object or by providing an air flow transverse to the direction of movement of the melted metal drops, or both.

An extractor system includes a negative pressure gas stream source, a negative pressure conduit, a positive pressure gas stream source, a plurality of positive pressure gas stream manifolds, and an operator interface. The negative pressure conduit is conveys the negative pressure gas stream from a work area. A first end of the negative pressure conduit is coupled to the negative pressure gas stream source, such that the negative pressure gas stream flows from the work area through a second end of the negative pressure conduit and toward the first end of the negative pressure conduit. The positive pressure gas stream manifolds are disposed about the negative pressure conduit at the second end of the negative pressure conduit, and fluidly coupled to the positive pressure gas stream source. The positive pressure gas stream is directed through the plurality of positive pressure gas stream manifolds. The operator interface allows a user to control the positive pressure gas stream through each of the plurality of positive pressure gas stream manifolds.

Embodiments of welding work cells are disclosed. One embodiment includes a workpiece positioning system, a welding power source, and a welding job sequencer. The workpiece positioning system powers an elevating motion and a rotational motion of a workpiece mounted between a headstock and a tailstock to re-position the workpiece for a next weld to be performed. The welding power source generates welding output power based on a set of welding parameters of the power source. The welding job sequencer commands the workpiece positioning system to re-position the workpiece from a current position to a next position in accordance with a next step of a welding sequence of a welding schedule. The welding job sequencer also commands the welding power source to adjust a current set of welding parameters to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule.

Embodiments of welding work cells are disclosed. One embodiment includes a workpiece positioning system, a welding power source, and a welding job sequencer. The workpiece positioning system powers an elevating motion and a rotational motion of a workpiece mounted between a headstock and a tailstock to re-position the workpiece for a next weld to be performed. The welding power source generates welding output power based on a set of welding parameters of the power source. The welding job sequencer commands the workpiece positioning system to re-position the workpiece from a current position to a next position in accordance with a next step of a welding sequence of a welding schedule. The welding job sequencer also commands the welding power source to adjust a current set of welding parameters to a next set of welding parameters in accordance with the next step of the welding sequence of the welding schedule.

The present application relates to a welding system comprising a main module provided with an outer casing identifying an input port for the connection to a source of external electrical power, an electric generator configured to adapt the electrical characteristics of said electrical power to a first type of welding, at least an output port for the connection to a welding torch, an electronic control unit configured to control the functionality of said electric generator. Said main module comprises a mechanical and electrical connection unit of a first type, said welding system comprising at least an auxiliary module provided with an outer casing identifying an electric generator configured to adapt the electrical characteristics of an electrical power to a second type of welding, at least a mechanical and electrical connection unit of a second type couplable to said mechanical and electrical connection unit of a first type.

A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.