Embodiments of systems and methods of additive manufacturing are disclosed. In one embodiment, a computer control apparatus accesses multiple planned build patterns corresponding to multiple build layers of a three-dimensional (3D) part to be additively manufactured. A metal deposition apparatus deposits metal material to form at least a portion of a build layer of the 3D part. The metal material is deposited as a beaded weave pattern, based on a planned path of a planned build pattern, under control of the computer control apparatus. A weave width, a weave frequency, and a weave dwell of the beaded weave pattern are dynamically adjusted during deposition of the beaded weave pattern. The adjustments are under control of the computer control apparatus based on the planned build pattern, as a width of the build layer varies along a length dimension of the build layer.

An arc welder produces a weave pattern between workpieces. Each weld run comprises a center portion including a joining region between the workpieces and edge regions spaced apart from the joining region. The welder includes a power source that provides a welding waveform to a welding electrode to generate an arc to achieve a desired heat for welding, a welding torch, and an oscillator for oscillating the torch between the welding edge regions. A controller causes the power source to operate in a first mode utilizing a first waveform during welding within the joining region, and in a second mode using a second waveform, having a greater positive component than the first waveform, during welding within the edge regions. The controller determines a stickout value based on the first waveform but not the second waveform, and performs seam tracking based the second waveform but not the first waveform.

An arc-tracking welding method according to the present invention is an arc-tracking welding method in a consumable-electrode-type welding apparatus provided with a weaving function for swinging a torch in the welding direction, wherein a welding current and a welding voltage to be supplied to a consumable electrode include high-frequency components. A change in resistance value resulting from a fluctuation in electrode height is detected from the welding current and the welding voltage during welding. Then, a shift of a weld line is detected from information about the detected resistance value and both end positions of a weaving amplitude.

An arc sensor adjustment device and adjustment method for carrying out highly-accurate copying control. A welding system includes a welding torch, a welding power source that supplies power to the welding torch, a robot and a robot controller that cause the welding torch to oscillate, and an arc sensor that obtains a welding current or a welding voltage generated during welding while oscillating the welding torch. The arc sensor obtains a welding current or a welding voltage generated during calibration, in which welding is carried out while oscillating the welding torch in an up-down direction, calculates, on the basis of the obtained welding current or welding voltage, a correction amount for the position of the welding torch during welding carried out while oscillating the welding torch in a left-right direction, and applies the calculated correction amount to copying control.

The invention relates to the field of construction, particularly to welding of above- and underground high-strength pipelines with controlled heat input. Application of the invention will increase the load-bearing capacity of the pipelines made with the use of butt-welded pipes, pipe spools, pipe strings. The method includes joining of two or more cylindrical metal pipes, pipe spools and pipe strings by the welded ring butt with the use of the arc welding for the whole perimeter of the pipe. Criteria for a high-quality welded joint include optimal selection of parameters of the welding thermic cycle. The suggested welding method allows to have the optimal structure, high strength and viscoplastic properties in areas of the welded joint, to provide for the required load-bearing capacity of the pipeline and its reliability during operation.

A welding method includes feeding a welding electrode axially from a welding torch, moving the welding electrode radially in a desired pattern with respect to a central axis of the welding torch by a motion control assembly within the welding torch, transmitting from control circuitry a signal corresponding to a position of the welding electrode relative to a weld joint or weld pool, advancing the welding torch or a workpiece to establish a weld, and transferring material from the welding electrode to a first location in an area of the weld pool. The welding electrode moves radially while feeding the welding electrode from the welding torch, the material from the welding electrode is transferred to the first location during a first cycle of the desired pattern, and the first location is controlled based at least in part on the signal.

A rail welding method and device are provided. The method includes: welding a bottom of rail, wherein welding is repeatedly performed along a first swing trajectory in a lengthwise direction of a weld seam, from one end of the bottom of rail to the other end of the bottom of rail; welding a waist of rail, wherein welding is repeatedly performed in the lengthwise direction of the weld seam along a second swing trajectory, from one end of the waist of rail, and the second swing trajectory is divided into two regions for respective welding in a width direction of the weld seam; and welding a head of rail, wherein welding is performed in the lengthwise direction of the weld seam along the first swing trajectory, between one end of the head of rail and the other end of the head of rail.

A welding method includes feeding a welding electrode axially from a welding torch, moving the welding electrode radially in a desired pattern with respect to a central axis of the welding torch by a motion control assembly within the welding torch, transmitting from control circuitry a signal corresponding to a position of the welding electrode relative to a weld joint or weld pool, advancing the welding torch or a workpiece to establish a weld, and transferring material from the welding electrode to a first location in an area of the weld pool. The welding electrode moves radially while feeding the welding electrode from the welding torch, the material from the welding electrode is transferred to the first location during a first cycle of the desired pattern, and the first location is controlled based at least in part on the signal.

Disclosed is a system having a robotic welding system, a controller, a camera, and a processor. The robotic welding system is configured to weld metal sections together in accordance with a plurality of welding variables. The controller is configured to automatically control the robotic welding system. The camera captures sequential images of the welding performed by the robotic welding system. According to an embodiment, the processor is configured to process the sequential images to determine when a selected welding state is to change to a next welding state based on the selected welding state and multiple consistent determinations of the next welding state, and to signal that change to the controller to effect a change in how the welding is performed by the robotic welding system. By considering multiple consistent determinations of the next welding state, there can be a high probability that the next welding state is correct.

A robotic electric arc welding system includes a welding torch, a welding robot configured to manipulate the welding torch during a welding operation, a robot controller operatively connected to the welding robot to control weaving movements of the welding torch along a weld seam and at a weave frequency and weave period, and a welding power supply operatively connected to the welding torch to control a welding waveform, and operatively connected to the robot controller for communication therewith. The welding power supply is configured to sample a plurality of weld parameters during a sampling period of the welding operation and form an analysis packet, and process the analysis packet to generate a weld quality score, wherein the welding power supply obtains the weave frequency or the weave period and automatically adjusts the sampling period for forming the analysis packet based on the weave frequency or the weave period.