An arc welding method preforms reciprocating wire feed so as to alternately perform forward feed and reverse feed. The arc welding method includes a normal arc welding step, a normal short circuit welding step, and an abnormal arc welding step. In the abnormal arc welding step, a short circuit state occurs at a second time point, which is before a lapse of a second period from a first time point at which an arc state occurs. Further, in the abnormal arc welding step, the reciprocating wire feed continues until a third time point after a lapse of a first period from the second time point. At the third time point, the reciprocating wire feed is stopped and the abnormal arc welding step is completed. From the third time point, the welding wire is decelerated and the reciprocating wire feed is restarted.

Apparatuses, systems, and/or methods for securing and unsecuring a wire feeder in an automatic welding system without using tools are disclosed. The welding system can include, for example, a robotic arm with a welding torch, an adaptor, and a wire feeder. The adaptor can include, for example, a quick-disconnect member located on the robotic arm. The wire feeder that can be removed from the adaptor after the quick-disconnect member has been actuated. The wire feeder can be installed and secured with tools by placing the wire feeder in the actuator and actuating the quick-disconnect member of the actuator.

The present disclosure provides a welding system having a welder, a welding gun, and a welding gun adapter, the welding gun being a spool gun with an attached motor. The welding gun adapter receives welding power from the welder, and converts it to output power suitable for driving the motor of the welding gun. The welding gun adapter also uses received welding power from the welder for control power. The present techniques allow for the use of welding guns requiring motor power to be used with any ordinary welder.

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.

A system and method to correct for deposition errors during a robotic welding additive manufacturing process. The system includes a welding power source to sample instantaneous parameter pairs of welding output current and wire feed speed in real time during a robotic welding additive manufacturing process while creating a current weld layer of a 3D workpiece part. An instantaneous ratio of welding output current and wire feed speed are determined for each instantaneous parameter pair. A short term running average ratio is determined based on the instantaneous ratios. A relative correction factor is generated based on at least the short term running average ratio and is used in real time while creating the current weld layer to compensate for deviations in a deposit level from a desired deposit level for the current weld layer.

A material processing system includes a power supply and a wire feeder to feed a wire electrode for a material processing operation. The enthalpy and/or temperature of a region of the tip of the electrode is maintained substantially constant via closed loop control. The control may be based upon regulation of current applied to the electrode. The control of the current may be based upon an electrode extension error. Wire feed speed may also be controlled to assist in maintaining a substantially constant enthalpy and/or temperature near the electrode tip.

Some examples of the present disclosure relate to a cover cap for a welding torch. The cover cap is attached to a housing of the welding torch and rotatable between a closed position, where the cover cap covers an access port of the welding torch, and an open position, where the cover cap does not cover the access port. The welding torch may have welding components within the handle that may be accessed through the access port when the cover cap is in the open position. A cap holder may be used to hold the cover cap in the open position.

A harmonic welding wire oscillator configured to oscillate a stretch of welding wire within a wire liner. The oscillator may include an actuator configured to oscillate the welding wire at a resonant frequency of the stretch of welding wire. The oscillation causes reciprocation of the welding wire at the tip of the welding torch.

A robot controller includes a contact detection unit that detects contact of a welding wire protruding from a welding torch with a welding target, an override-value adjustment unit that sets and changes an override value for increasing or decreasing an operating speed of the robot from a predetermined speed, and a control unit which receives an operation signal from a teaching operation device and that controls the robot according to the operation signal at the operating speed based on the override value which is set by the override-value adjustment unit. When the contact of the welding wire with the welding target is detected by the contact detection unit, the control unit temporarily stops the robot, and the override-value adjustment unit decreases the override value.

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.