A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

A welding system includes at least one high intensity energy source to create a weld puddle during a root pass on a narrow joint of a workpiece with a clad layer. The system also includes a controller to control a weld ramp out process such that, as the molten puddle advances to a start of an existing root pass weld, the controller at least one of decreases an energy output of the at least one high intensity energy source and reduces an interaction time between the at least one high intensity energy source and the weld puddle. After completion of the root pass, a thickness of a root pass weld in a region that is at or near the start point of the existing root pass weld is in a range of 100 percent to 130 percent of a nominal root pass thickness of a remainder of the root pass weld.

The present disclosure relates generally to an improved design of a metal-cored welding wire electrode for use on a high deposition rate welding process that resistively preheats the wire prior to being subjected to the welding current. The preheat circuit reduces the welding current drawn by the electrode so that higher wire feed speeds, and thus higher deposition rates, may be obtained. The metal-cored welding wire includes both a higher fill rate (a greater percentage of the welding wire is the granular core) along with added sulfur and an added bead wetting agent. The bead wetting agent may be one or more of selenium, tellurium, arsenic, gallium, bismuth, and tin. The improved metal-cored welding wire leads to an enhanced weld deposit appearance that means the weld deposits are less likely to be rejected as unusable.

Systems, methods, and apparatus to control welding electrode preheating are disclosed. An example consumable electrode-fed welding-type system includes a welding-type current source configured to provide welding-type current to a welding-type circuit, the welding-type circuit comprising a welding-type electrode and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the welding-type electrode via a second contact tip of the welding torch; an electrode preheating control circuit configured to adjust at least one of the preheating current or an electrode feed speed based on the change in the contact-tip-to-work-distance; and a current interpreter configured to determine a change in a contact-tip-to-work-distance of the welding torch based on at least one of the welding-type current or the preheating current.

A welding system configured to eliminate effects of arc blow in a welding operation. The welding system comprises welding circuitry, preheat circuitry, a drive roller, and control circuitry configured to perform a reciprocation cycle. The reciprocation cycle may include the steps of: advancing a filler material toward the welding work piece until the filler material is electrically connected to the weld pool; supplying the preheat power to heat the filler material while the filler material is electrically connected to the weld pool; retracting the filler material away from the welding work piece until the filler material is not electrically connected to the weld pool; and terminating supply of the preheat power to the filler material while the filler material is not electrically connected to the weld pool.

A welding system configured to eliminate effects of arc blow in a welding operation. The welding system comprises welding circuitry, preheat circuitry, and control circuitry configured to switch the welding circuitry and the preheat circuitry between power levels asynchronously during the welding operation. The control circuitry configured to switch the welding circuitry and the preheat circuitry between power levels asynchronously such that the preheat circuitry is switched to the second preheat power level when the welding circuitry is switched to the first welding power level and the preheat circuitry is switched to the first preheat power level when the welding circuitry is switched to the second welding power level.

An example welding-type system includes: power conversion circuitry configured to convert input power to welding-type power; an interface configured to: receive a selection of a parameter from a plurality of parameters; and receive a selection of a value for the selected parameter; and control circuitry configured to: in response to the selection of the parameter from the plurality of parameters, control the interface to output a visual indication of an effect of changing the parameter on at least one of a welding electrode, a quantity of discontinuities in the weld, a magnitude of a discontinuity in the weld, or a quantity of inclusions in the weld; in response to a change in the value of the selected parameter via the interface, control the interface to change the visual indication of the effect based on the change in the value; and control the power conversion circuitry based on the value.

Systems, methods, and apparatus to weld by preheating welding wire and inductively heating a workpiece are disclosed. An example welding system includes: a welding current source configured to provide welding current to a welding circuit, the welding circuit comprising an electrode wire and a first contact tip of a welding torch; an electrode preheating circuit configured to provide preheating current through a first portion of the electrode wire via a second contact tip of the welding torch; and at least one induction heating coil configured to apply induction heat to a workpiece, the welding current source, the electrode preheating circuit, and the induction heating coil configured to perform a preheating operation and a welding operation on the workpiece.

The present disclosure is directed to systems and methods for pretreating a wire that is used in a welding operation to reduce the amount of hydrogen introduced into a weld. Using embodiments of the systems and methods disclosed herein, one passes a wire through a pre-treatment chamber in which a wire is treated to release hydrogen and/or other contaminants, and provides a gas flow through the pre-treatment chamber so that the contaminants that are released from the wire are taken up by the gas. The gas exiting the pre-treatment chamber may be isolated from the shielding gas utilized during a welding operation. For instance, the pretreatment gas may be directed away from the distal end of the welding torch, thereby preventing released contaminants from being transported into a weld.

An apparatus and system for preheating and removing surface oxidation of welding wire using electric arcs one via three or more tungsten electrodes connected to a polyphaser preheating power source is disclosed. Electric arc preheating of welding wire allows increased efficiency and deposition rates.