A computerized method is provided for selecting a direction of formation of a slag puddle on a workpiece during processing of the workpiece by a thermal processing torch. The method comprises causing the torch to emit a thermal arc to gouge the workpiece at a first location without piercing through the workpiece. The method also includes translating the torch from the first location to a second location along a first direction on the workpiece while the torch is gouging the workpiece, the first direction substantially along the selected direction of slag puddle formation. The gouging and translating cause formation of a trench in a surface of the workpiece in the first direction. The method further includes causing the thermal arc emitted by the torch to pierce through the workpiece at the second location, which causes the formation of the slag puddle along the selected direction as guided by the trench.

An example welding power supply includes: power conversion circuitry configured to convert supply power to welding current and to output the welding current to at least one of a shielded metal arc welding (SMAW) electrode or a gouging torch; a voltage sense circuit configured to measure an output voltage of the power conversion circuitry; and control circuitry configured to: control the power conversion circuitry using a current-controlled control loop based on a target current; while the output voltage is above a lower voltage limit, control the target current based on a difference between a reference voltage and the output voltage; and in response to detecting that the output voltage has decreased below the lower voltage limit, control a welding current output by the power conversion circuitry based on a first exponential relationship.

A robotic welding systems and related methods are described. In some embodiments, a robotic welding system may generate a target trajectory based at least partly on a trajectory of a welding torch during manual operation of the welding torch; and operate one or more actuators of the system to control movement of the welding torch based at least partly on the target trajectory.

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 method and apparatus are provided for late-customization of a valve body having an initial valve body configuration having a first end connection and a second end connection. The method includes receiving a selection of (i) a generic valve body, (ii) a first end connection, and (iii) a second end connection. The method further includes adjoining the first and second end connections to the valve body using an iterative welding process. The apparatus is configured to receive a generic valve body having an initial end configuration and to receive a different end configuration. Ends are connected to the valve body subject to an initial bias and a comparison between actual results and predicted results, and first end connection is iteratively welded.

A welding-type power system that includes an engine and an electric generator driven by the engine. A power bus configured to connect a power output of the electric generator to one or more of a welding-type output, a power storage device, and a switched mode power supply. A plurality of sensors are configured to monitor a plurality of parameters associated with power demand to and from the power bus and generate a signal indicative of the power demand to and from the power bus based on the monitored plurality of parameters. A controller is configured to receive the signal from the plurality of sensors, the controller to control the engine speed in response to the signal or the power demand.

The present invention provides a work piece processing system for operating on a work piece or at least one component of a work piece. The processing system includes a base system for transporting the at least one work piece component, at least one processing head for operating on the work piece component, and means for controlling, the means for controlling the processing system. In a first embodiment, the processing system further includes a support structure, the support structure including at least one frame member having a track. Here, the at least one processing head travels along the track. In a second embodiment, the processing system further includes a multi-linkage robotic arm, the robotic arm including a plurality of rotary joints and a plurality of arm segments interconnecting the rotary joints. Here, the at least one processing head is operably mounted to a free end of one of the plurality of arm segments.

A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

A welding-type system with a programmed controller and alert devices for alerting a user as to the impending thermal shutdown of the welding-type system.

Methods and apparatus to control hot-start weld current for arc ignition are disclosed. An example welding-type power supply includes a power converter to output welding-type current, a temperature monitor to determine a temperature of an electrode using at least one of a temperature measurement or a thermal model, and a current controller to control a hot-start weld current output by the power converter based on the temperature of the electrode.