Embodiments of the present invention are directed to systems and methods of controlling wire feeding in a welding operation, where the wire feeding has a plurality of positive and negative pulses. Embodiments determine an average wire feed speed and compare the average to a desired wire feed speed and then change a parameter of the wire feed pulses to achieve a desired wire feed speed.

Disclosed is a welding system configured to perform additive manufacturing using a controlled short circuit welding process to apply a plurality of droplets of a wire to create a multilayer part comprised of the droplets. Operational parameters of the additive manufacturing system are dynamically adjusted based on data representing a temperature value and/or a geometric characteristic of the part. Based on the data, the controller can adjust one or more operational parameters to control application of droplets to build up the part.

There is provided an arc welding control method of feeding a welding wire according to a push-pull feeding control using a push-side feeding motor which rotates in a forward feeding direction at a feeding rate set to a push feeding-rate setting value and a pull-side feeding motor which alternates a forward feeding rotation and a reverse feeding rotation periodically, and generating short-circuiting periods and arc periods to perform welding. An average feeding rate of the pull-side feeding motor is detected. The push feeding-rate setting value is corrected to the detected average feeding rate of the pull-side feeding motor.

There is provided an arc welding control method of feeding a welding wire according to a push-pull feeding control using a push-side feeding motor which rotates in a forward feeding direction at a feeding rate set to a push feeding-rate setting value and a pull-side feeding motor which alternates a forward feeding rotation and a reverse feeding rotation periodically, and generating short-circuiting periods and arc periods to perform welding. An average feeding rate of the pull-side feeding motor is detected. The push feeding-rate setting value is corrected to the detected average feeding rate of the pull-side feeding motor.

In an arc start control method for forward and reverse feed arc welding in which forward and reverse feed control of alternately switching a feed speed Fw of a welding wire between a forward feed period and a reverse feed period is performed to generate a short circuit period and an arc period to perform welding, at arc start, a pulse period Tp during which a pulse current is energized for a plurality of number of times is provided, and thereafter forward and reverse feed control is started from forward feed period of the welding wire. During the pulse period Tp, a forward feed speed Fp of the welding wire is set so that the arc period is continuous. In addition, the forward feed speed Fp is changed based on a time length of pulse period Tp and/or a value of a welding voltage Vw during pulse period Tp.

An arc welding control method for controlling welding in which a material of a welding wire is aluminum or an aluminum alloy, and a feed speed Fw of the welding wire is alternately switched between a forward feed period and a reverse feed period to repeat a short circuit period and an arc period, a welding current Iw is controlled so that an average value of maximum values of the welding current Iw during the short circuit period is 150 A or less. A reverse feed peak value Wrp during the reverse feed period is set so that an average value of time lengths of the short circuit period is 7 ms or less. Accordingly, the current value can be reduced when the short circuit is released and the lengthening in the short circuit period can be prevented, so that the spatter generation amount can be reduced.

An arc welding control method for controlling welding in which a material of a welding wire is aluminum or an aluminum alloy, and a feed speed Fw of the welding wire is alternately switched between a forward feed period and a reverse feed period to repeat a short circuit period and an arc period, a welding current Iw is controlled so that an average value of maximum values of the welding current Iw during the short circuit period is 150 A or less. A reverse feed peak value Wrp during the reverse feed period is set so that an average value of time lengths of the short circuit period is 7 ms or less. Accordingly, the current value can be reduced when the short circuit is released and the lengthening in the short circuit period can be prevented, so that the spatter generation amount can be reduced.

A method of preventing arc flaring events for a welding system is provided. The method includes determining, by a controller, a real-time welding output characteristic of the welding system. The method additionally includes comparing, by the controller, the real-time welding output characteristic to a threshold welding output characteristic. The method further includes controlling an operating characteristic of the welding system in response to a determination that the real-time welding output characteristic exceeds the threshold welding output characteristic.

Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.

A method for encoding information includes specifying a digital value and providing a symbol (28, 70, 80, 90, 100) comprising a plurality of polygons (72, 82, 92, 94, 102) meeting at a common vertex (74, 84, 96, 98, 104) and having different, respective colors selected so as to encode the specified digital value.