Systems, methods, and apparatus to provide preheat voltage feedback loss protection are disclosed. An example welding-type system includes a welding-type power source configured to provide welding-type power 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 power through a first portion of the welding-type electrode via a second contact tip of the welding torch; a preheat feedback circuit configured to measure a preheat voltage; and an electrode preheat control circuit configured to: control the preheating power based on the preheating voltage; and control the electrode preheating circuit to reduce the preheating power in response to detecting an invalid preheat voltage measured by the preheat feedback circuit.

The invention relates to a welding device (1) having a welding torch (2), a feeder (3) for feeding a melting filler material (4) at a feed rate (v) to a weld (S), where the filler material (4) is melted with the aid of an electric arc (L), and a pre-heater (9) for heating the filler material (4) upstream of the weld (S) by means of a laser beam (7) having a laser power (P) and generated in a laser device (6). For space-saving and safe heating of the filler material (4) upstream of the weld (S), the pre-heater (9) includes a feed channel (5) for the filler material (4), and at least one deflector (8) is attached to the pre-heater (9) for deflecting the laser beam (7) to the filler material (4) in such a way that the laser beam (7) strikes the filler material (4) inside the feed channel (5) of the pre-heater (9).

The present disclosure describes devices and methods directed at an improved system capable of achieving ultra-high deposition rates. In particular, devices and methods are described for implementing a welding system that includes a GMAW welding system and a hot wire welding system in order to achieve ultra-high deposition rates. In general, the welding system includes a consumable cored welding wire that serves as an electrode. The consumable cored welding wire that includes one or more alkaline earth metal elements at a concentration between 0.005% and 10% on the bases of total weight of the consumable cored welding wire. The hot wire welding system includes a consumable hot wire configured to be positioned into a molten weld pool created by the melted consumable cored welding wire.

An example welding power supply includes: a power input configured to receive alternating current (AC) input power; and power conversion circuitry configured to: convert a first portion of the input power to welding power; output the welding power to a weld circuit; convert a second portion of the input power to preheating power; and output the preheating power to a preheater.

In a method for regulating or controlling the conveyance speed of a wire composed of consumable material during a laser soldering or welding method, the wire is melted by a laser beam from a laser unit and is conveyed at a mean conveyance speed toward a workpiece to be processed, wherein a voltage between the wire and the workpiece is measured. A laser soldering or laser welding device carries out this method. In order to avoid at least relatively lengthy short-circuit breaking between the end of the wire and the workpiece, the conveyance speed of the wire, as a function of the measured voltage, is temporarily increased to a predetermined boost speed by increasing the conveyance speed to the predetermined boost speed when a defined voltage limit value is exceeded, and the conveyance speed is reduced again at the latest when the voltage limit value falls below.

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.

Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.

Embodiments of welding systems and methods with coordinated dual power outputs supporting a same welding process or a same AC output process are disclosed. One embodiment of a welding system includes an engine and a generator operatively connected to the engine, where the engine is configured to drive the generator to produce electrical input power. The welding system also includes a power supply operatively connected to the generator and having at least one controller. The power supply is configured to convert the electrical input power to form two power outputs that are coordinated with each other, at least in time, via the controller to support a same welding process. The same welding process may be, for example, a hotwire welding process, a tandem metal inert gas (MIG) welding process, or an alternating current (AC) output process.

An example welding power supply includes: power conversion circuitry configured to convert input power to wire preheating power, and to output the wire preheating power to a preheating system; and control circuitry configured to control the power conversion circuitry based on a temperature model to preheat an electrode wire to a target temperature via the preheating system.

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.