Methods and apparatus to communicate via a welding arc are disclosed. An example welding-type power supply includes a power converter, a weld monitor, and an arc modulator. The power converter outputs welding power to sustain a welding-type arc at a welding-type torch. The weld monitor monitors one or more aspects of a weld performed using the welding-type arc and the welding-type torch, and selects an audio message based on the one or more aspects. The arc modulator configured to modify the welding-type arc to output the selected audio message as a plasma speaker.

Embodiments of a welding power supply include an engine adapted to drive a generator to produce a first power and a energy storage device adapted to discharge energy to produce a second power. The welding power supply also includes control circuitry adapted to detect a commanded output. The control circuitry is adapted to meet the commanded output by controlling access to power from the energy storage device to produce the second power when the commanded output is below a first predetermined load level. The control circuitry is further adapted to meet the commanded output by controlling access to power from the engine and the energy storage device to produce the first power and the second power when the commanded output is above a second predetermined load level.

Embodiments of the present disclosure are directed toward an energy storage caddy configured to be coupled to a secondary side of a welder. The energy storage caddy is configured to combine a first power output of the welder with a second power output of the energy storage caddy to produce a total power output for a welding system.

Engine driven power supplies with output reduction are disclosed. An example engine-driven welding power supply for providing a welding-type output includes an engine, a generator mechanically linked to the engine, power conditioning circuitry, and a controller. The generator generates output power based on mechanical input from the engine. The power conditioning circuitry converts the output power from the generator to welding-type power based on a commanded output. The controller reduce an output of the power conditioning circuitry from the commanded output by an amount proportional to a difference between a speed of the engine and a commanded engine speed while monitoring the difference, decreases the output in response to determining that the reduction in the output does not result in an acceleration in the engine speed, and increases the welding-type output as the difference between the speed of the engine and the commanded engine speed decreases.

An energy storage module (ESM) is provided for connecting to a welding or cutting machine (WCM). The ESM has a controller for connecting to a communication link (CM) to communicate with the WCM when the ESM is connected to the WCM. The ESM also has a battery pack to store electrical energy and output DC electrical power to be used by the WCM, under control of the controller. Electrical input power provided to the WCM from an electrical grid or a renewable energy source during a welding or cutting operation can be supplemented or replaced by the DC electrical power from the ESM. The ESM further has regulation circuitry to regulate the DC electrical power output from the battery pack. The controller controls the regulation circuitry based on identification data received over the CM from the WCM to regulate the DC electrical power to be electrically compatible with the WCM.

The present application relates to an arc welding arrangement and an electric arc welding method to be used with the arc welding arrangement. The arc welding arrangement comprising a first power source, a first electrode connected to say first power source, and a second electrode, said first electrode being adapted to generate a weld pool via a first electric arc present within a first arc region. The second electrode is operated at welding parameters adapted to ensure that excess energy from at least said first electrode is required to maintain said second arc ignited. The method comprises the step of feeding said second electrode so that it is allowed to consume excess energy from said first electrode to maintain said second arc ignited.

Embodiments are directed to an orbital welding system, including customized orbital weld head fixtures, and computer-controlled programs for performing homogeneous orbital welds. In one scenario, an orbital welding system includes a controller, a shield gas supply system that supplies gases to an orbital welding tool, an electrical supply system that supplies an electrical current to the orbital welding tool, and the orbital welding tool, which includes a welding electrode that is configured to weld two or more items together using the supplied electrical current and the gases supplied by the gas supply system. The controller generates control signals that direct the orbital welding tool, the electrical supply system, and the gas supply system to homogeneously orbital weld the at least two items together, so that the at least two items are homogeneously welded together without using a filler material. Various other methods, systems, and apparatuses are also described.

An end assembly for use with a welding device having a contact tip, a diffusor body, and a gooseneck. The contact tip has a convex end surface that contacts and mates with a concave end of the diffuser body. The diffuser body forms a blind bore forming central web and a series of passageways. A longitudinal passageway segment is formed in the contact tip parallel with the central longitudinal electrode bore of the contact tip. A second passageway segment joins the first longitudinal passageway segment. When the contact tip is affixed to the diffuser body, a chamber is formed at the base of the contact tip communicating with the diffuser body passageways. Shielding gas that flows into the diffuser body passes through the web passageways into the chamber and through the first and second passageways of the contact tip to provide shielding gas to the weld site and cool the contact tip during welding operations.

A method includes ramping down a welding current, generated by a power supply, that reaches a welding zone via a welding circuit, storing inductive energy from the welding circuit that is generated as a result of the ramping down to obtain stored energy, and selectively feeding the stored energy to the welding circuit.

A system and device operating using a welding power bus are provided. One welding power supply includes control circuitry configured to control the operation of the welding power supply and power conversion circuitry configured to convert input power to output welding power. The welding power supply also includes welding terminals configured to receive the output welding power from the power conversion circuitry and to provide the output welding power to a device that does not use the welding power for a welding operation. The control circuitry is configured to adapt the output welding power to the device.