A method for controlling a start of a metalworking operation. The method includes detecting an initial contact between a wire being fed from a welding apparatus and a workpiece and, in response to the detection, halting feeding of the wire from the welding apparatus. The method further includes activating a high energy heat source configured to heat a tip of the wire and resuming the feeding of the wire from the welding apparatus when the tip of the wire is heated by the high energy heat source to a plastic state. The feeding of the wire is resumed by measuring a force feedback from the wire contacting the workpiece. An apparatus for implementing the method is also disclosed.

Provided is a fluid-cooled melting tool that can be used in methods and systems for manufacturing objects by additive manufacturing techniques, especially titanium and titanium alloy objects. In some configurations, the melting tool is configured to be a plasma transferred arc (PTA) torch and the deposition rate can be increased by increasing the flow rate of electric charge through the electrode made possible by the dual circuit cooling design of the torch. The fluid-cooled melting tools provided herein exhibit stable and repeatable PTA characteristics over wide range of current including current of 400 amps or more, whether pulsed or non-pulsed, and plasma gas flow inputs.

An optical manufacturing process sensing and status indication system is taught that is able to utilize optical emissions from a manufacturing process to infer the state of the process. In one case, it is able to use these optical emissions to distinguish thermal phenomena on two timescales and to perform feature extraction and classification so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process. In other case, it is able to utilize these optical emissions to derive corresponding spectra and identify features within those spectra so that nominal process conditions may be uniquely distinguished from off-nominal process conditions at a given instant in time or over a sequential series of instants in time occurring over the duration of the manufacturing process.

In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

In some aspects, material processing head can include a body; an antenna disposed within the body; a first tag, associated with a first consumable component, disposed within a flux communication zone of the body at a first distance from the antenna, the first tag having a first resonant frequency; and a second tag, associated with a second consumable component, disposed within the flux communication zone of the body at a second distance from the antenna, the second tag having a second resonant frequency that is different than the first resonant frequency, where the first and second resonant frequencies are tuned based upon at least one of: i) a difference between the first distance and the second distance; or ii) a characteristic (e.g., shape) of the flux communication zone in which the first tag and/or the second tag is disposed.

The invention relates to a method for producing, in particular generatively producing, and coding a three-dimensional component. Said method comprises the following steps: providing a starting material, supplying a process gas to the starting material, melting the starting material by means of a heat source, and repeating the aforementioned steps. The method according to the invention is characterized in that, at least at a predetermined time interval during the melting of the starting material, a coding component or a coding gas containing a coding component is added to the process gas such that the use of the coding component in the finished object is detectable, and coding information is logged which describes the coding information and the location thereof in the component.

The present disclosure provides a method of all-position plasma welding process for titanium alloy pipeline, which may be used for welding a titanium alloy pipeline made of TA2 or TC4, with a wall thickness of 3˜16 mm, and a pipe diameter of 108 mm or more. When the wall thickness is 3˜9 mm, a keyhole type technology may be used for one-time welding formation, and when the wall thickness is 9˜16 mm, grooving treatment needs to be performed for the pipeline, and the keyhole type technology is used for backing welding, and then filling welding and covering welding are performed using filler wire welding through a melt-in technology. The method includes following steps: S1: performing pre-welding treatment for the pipeline; S2: clamping the pipeline; S3: setting welding parameters; S4: starting the welding.

The present disclosure provides a method of all-position plasma welding process for titanium alloy pipeline, which may be used for welding a titanium alloy pipeline made of TA2 or TC4, with a wall thickness of 3˜16 mm, and a pipe diameter of 108 mm or more. When the wall thickness is 3˜9 mm, a keyhole type technology may be used for one-time welding formation, and when the wall thickness is 9˜16 mm, grooving treatment needs to be performed for the pipeline, and the keyhole type technology is used for backing welding, and then filling welding and covering welding are performed using filler wire welding through a melt-in technology. The method includes following steps: S1: performing pre-welding treatment for the pipeline; S2: clamping the pipeline; S3: setting welding parameters; S4: starting the welding.

A nozzle gas flow sensor and a method thereof are provided. The nozzle gas flow sensor includes circuitry configured to receive sensing signals (readings) from a sensing element, each indicative of a flow rate of shielding gas ejected from a nozzle of a torch; analyze the flow rate; and evaluate the stability of the flow rate of the shielding gas with a window of operation. The nozzle gas flow sensor may include an indicator indicative of the evaluation result. The torch may be a welding torch, a cutting torch and/or a spraying (coating) torch.

Systems and methods are disclosed that include an operation chamber, a plasma generator having at least one plasma head disposed within the operation chamber and in proximity to a profile formed by cutting a piece of tubing, and a mechanical motion module. The plasma generator generates a plasma treatment and applies the plasma treatment via the at least one plasma head to the profile to activate material on an end surface of the profile, within a lumen of the profile, or a combination thereof. Once the material of the profile is activated by the plasma treatment, the mechanical motion module manipulates the profile to close the lumen of the profile to aseptically seal the profile.