A multi-process welding machine provides an intuitive user interface to enable a user to select among different welding processes, and to select parameters for a given selected welding process. The multi-process welding machine also provides an arrangement by which a switching module, or DC to AC converter, of an AC TIG unit can be controlled to alternatively supply AC or DC welding voltages or current. Further, a configuration of switches can be leveraged to automatically (or manually) control the polarity of welding cables for different processes and to engage or disengage a wire feeder when, e.g., a MIG welding process is selected, or not selected, respectively. Finally, in an embodiment, the ferrite or magnetic materials used for a main output inductor and an high frequency starting inductor of the welding machine can be combined.

A system may include a current source; a first metal or alloy component with a first major surface electrically coupled to the current source; a second metal or alloy component with a second major surface electrically coupled in series to the first component and the current source via an external electrical conductor, where the first and second major surfaces are positioned adjacent to each other to define a joint region; a metal or alloy powder disposed in at least a portion of the joint region; and a controller. The controller may be configured to cause the current source to output an alternating current that conducts through the first component and the second component to induce magnetic eddy currents, magnetic hysteresis, or both within at least a portion of the metal or alloy powder disposed in at least the first portion of the joint region.

Methods and system of the present invention include hot-wire welding system used in combination with arc welding systems, where the welding system initiates an arc clearing routine in hot-wire welding system. The arc clearing routine includes detection of an arc and then skipping a complete pulse of the hot-wire waveform and initiating the next pulse to determine is consumable separation still exists. Follow-on pulses are repeatedly initiated until it is determined that consumable separation does not exist, at which time the hot-wire operation is continued.

A welding regime may implements cyclic short circuits under a closed loop voltage control approach. Upon clearing or imminent clearing of the short circuit, a current recess is implemented. The current recess reduces the current that would otherwise be applied to the weld, resulting in multiple benefits. The recess may be implemented by suspending voltage command signals. Following the current recess, normal control is resumed with the then-current voltage command.

A welding power source is configured to supply a welding current to a wire as a consumable electrode. The welding power source includes a controller configured to change the welding current based on a position of a distal end of the wire a distance from which to a surface of a base metal varies periodically, in a case where the distal end of the wire is fed toward the base metal with periodical switching between a forward feeding period and a reverse feeding period.

A method and apparatus for welding is disclosed. The output is preferably a cyclical CV MIG output, and each cycle is divided into segments. An output parameter is sampled a plurality of times within one or more of the segments. The CV output is controlled within the at least one segment in response to the sampling. The parameter is output power, a resistance of the load, an output current, an output voltage, or functions thereof in various embodiments. The control loop is preferably a PI or PID loop. The loop may be applied only within a window. The set point may be taught or fixed. The system can be used to weld with a controlled arc length.

An arc welding apparatus includes: a detector configured to detect whether it is in a short state or an arc state between a consumable electrode and a welded article; a feed adjuster configured to apply a forward feed for feeding the consumable electrode when the arc state is detected and apply a reverse feed for feeding the consumable electrode when the short state is detected; a determiner configured to determine whether or not a predetermined period has elapsed after the detector has detected the short state; and an instructor configured to instruct the feed adjuster to continue the reverse feed even when the arc state is detected, until the determiner determines that the predetermined period has elapsed.

Disclosed is a welding-type power source that includes a first wire feeder provides a wire to a workpiece. A first wire feeder motor of the wire feeder to move the wire from a wire storage device to the workpiece. A second wire feeder motor moves the wire to and away from the workpiece and superimposes movement of the wire onto the movement from the first wire feeder motor. A moveable buffer located between the first and second wire feeder motors, and configured to accommodate a change in length of the wire between the first and second wire feeder motors when the second wire feeder motor moves the wire away from the workpiece. A sensor senses movement or displacement of the moveable buffer, wherein a speed or direction of the first or second wire feeder motors is adjusted based on data from the sensor.

There is provided an arc welding control method of performing a forward/reverse feeding control of alternating a feeding rate of a welding wire between a forward feeding period and a reverse feeding period, and generating short-circuiting periods and arc periods to perform welding. The welding wire is fed forwardly at a time of staring the welding. The forward/reverse feeding control is started from the reverse feeding period of the welding wire after starting conduction of a welding current.

A consumable electrode arc welding method using a shielding gas containing argon comprises: setting a first welding condition in which a first welding current is supplied to a welding wire; and setting a second welding condition in which a second welding current is supplied to a welding wire. The first welding condition and the second welding condition are welding conditions in which a reference current of the welding current is 350 A or higher and a current variation range is from 50 A to 150 A, and the first welding condition and the second welding condition are switched at a cycle of a frequency ranging from 1 Hz to 5 Hz.