Disclosed is a welding-type power source that includes a first wire feeder provides a wire to a workpiece. A first wire feeder motor of the wire feeder to move the wire from a wire storage device to the workpiece. A second wire feeder motor moves the wire to and away from the workpiece and superimposes movement of the wire onto the movement from the first wire feeder motor. A moveable buffer located between the first and second wire feeder motors, and configured to accommodate a change in length of the wire between the first and second wire feeder motors when the second wire feeder motor moves the wire away from the workpiece. A sensor senses movement or displacement of the moveable buffer, wherein a speed or direction of the first or second wire feeder motors is adjusted based on data from the sensor.

A welding-type system includes a wireless network interface configured to connect a wire feeder or power supply to a wireless network. The wireless network interface is also configured to receive a wireless command in a first format. The wireless command is configured to control the power supply. Moreover, the wireless network interface is configured to convert the wireless command from the first format to a second format. The welding-type system also includes a wired transceiver configured to transmit the converted wireless command across a power delivery cable to the power supply. Furthermore, the welding-type system includes power terminals configured to receive power from the power supply at a level based at least in part on the transmitted wireless command.

An arc welding control method for controlling welding in which a material of a welding wire is aluminum or an aluminum alloy, and a feed speed Fw of the welding wire is alternately switched between a forward feed period and a reverse feed period to repeat a short circuit period and an arc period, a welding current Iw is controlled so that an average value of maximum values of the welding current Iw during the short circuit period is 150 A or less. A reverse feed peak value Wrp during the reverse feed period is set so that an average value of time lengths of the short circuit period is 7 ms or less. Accordingly, the current value can be reduced when the short circuit is released and the lengthening in the short circuit period can be prevented, so that the spatter generation amount can be reduced.

A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

A system and method of welding or additive manufacturing is provided where at least two welding electrodes are provided to and passed through a two separate orifices on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes, where a bridge droplet is formed between the electrodes and then transferred to the puddle.

A plurality of wire guide modules are interconnected and pivotally attached to each other. The wire guide modules are pivotable between straight configuration and a curved configuration. Each wire guide module defines a channel (22) extending longitudinally therethrough with bearings (24, 26, 28) on opposite lateral sides of the channel. The wire guide modules are defined by first (10a) and second (10b) halves that are joined together to define the channel and retain the bearings. Each wire guide module defines a slot portion (40a) at a first end and tongue portion (42a) at the second end. The tongue portion is sized to be received within the slot portion. The tongue portion defines a pivot hole and the slot portion defines pivot pins received in the pivot hole to define the pivot axis therebetween.

A method and system to manufacture workpieces employing a high intensity energy source that irradiates a surface of a workpiece 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. Preferably, a wire feeding device feeds the wire to the puddle, and a power supply supplies a heating signal to the wire where the heating signal comprises a plurality of current pulses and where each of the current pulses creates a molten droplet on a distal end of the wire which is deposited into the puddle.

A data structure for weld programs associates configuration data for a welding system with a plurality of weld programs and weld sequence data. The data structure allows the welding system to be configured for a particular part, operator, or stage in a welding process, and to be easily reconfigured when the part, operator, or stage changes, providing improved efficiency and flexibility in operation.

A wire feeding system includes a first feeder provided with a first feeding motor that feeds a wire in a wire feeding direction, a second feeder spaced apart from the first feeder in the wire feeding direction and provided with a second feeding motor that feeds the wire in the wire feeding direction, and a controller that controls the rotation speed of the first feeding motor based on a first speed command and controls the rotation speed of the second feeding motor based on a second speed command. The controller gradually changes the second speed command over time when an amount of change of the second speed command is not within a predetermined range.

A welding system includes components equipped with digital communications circuitry for synchronization and coordination of tasks associated with the welding operation. The tasks may be initiated and terminated independently or in coordination based upon synchronization of this circuitry. Certain of the tasks may be performed by the components in an open-loop manner or in a closed-loop manner based upon feedback of welding parameters. Moreover, certain tasks may be independent of one another, or interdependent although carried out in parallel by the different system component.