A method of manufacturing using an additive manufacturing process includes providing a deposition system, the deposition system configured to provide a plurality of cells to form a blank of a part, depositing a first layer of the blank, the first layer comprising a first deposited cell, a second deposited cell spaced apart from the first deposited cell, and a third deposited cell spaced apart from the first deposited cell and the second deposited cell, and depositing a second layer of the part on the first layer, the second layer comprising a fourth deposited cell, a fifth deposited cell spaced apart from the fourth deposited cell, and a sixth deposited cell spaced apart from the fourth deposited cell and the fifth deposited cell. Each of the first layer and the second layer are formed using non-continuous deposition to form the blank.

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.

A welding torch includes a torch body and at least one device for feeding a consumable welding wire towards the tool center point that has an attachment device for attachment to the torch or an element connected thereto. A base support, which is connected to the attachment device, includes at least two deflection elements for guiding the wire towards the center point. The at least two deflection elements are arranged on the base support so that a first wire path length from the last deflection element located closest to the center point to the center point is shorter than a second wire path length between the last deflection element and a further deflection element as viewed counter to a main wire feed direction, and so that the arcuate wire has a greater segment height along the second path length than the segment height along the first path length.

A pulse arc welding device is controlled so as to alternately repeat a peak current period in which a welding current is a peak current and a base current period in which the welding current is a base current smaller than the peak current, feed a welding wire to an object at a feeding speed while the welding current flows through the welding wire, generate an arc between the welding wire and the object, and weld the object. So as to keep an arc length of the arc to be constant, in the base current period, the feeding speed is set to a first feeding speed and, in the peak current period, the feeding speed is set to a second feeding speed which is larger than the first feeding speed and corresponds to the first feeding speed. By this method, good welding quality with reduced spattering and suppressed undercut can be obtained.

A build-up welding method is disclosed in which a welding torch is guided along a metallic workpiece and at least one melting wire serving as a build-up material is fed at an infeed speed into the arc between at least one non-melting electrode of the welding torch and the workpiece. In order to achieve a build-up welding method with higher build-up speeds in comparison to the prior art, it is proposed for the non-melting electrode positioned normal to the workpiece to be guided along the workpiece and for the fed wire to also be moved back and forth along its infeed direction.

The invention is a system for the in-situ monitoring of additive manufacturing. The system, without pre-calibration of a test sample, utilizes ultrasonic waves to conduct a layer-by-layer analysis of a three-dimensional component as it is being developed on a build plate. Resonant frequencies for each layer is measured and the difference between the resonant frequencies of consecutive layers are calculated to define a baseline frequency. Similarities or differences in baseline frequencies are used to validate the integrity of the layers of the component, and also to determine if structural inconsistencies exists. Based on these determinations, the system decides whether to continue printing or to halt printing.

The purpose of the present invention is to reduce the amount of sputtering in a welding method wherein a welding wire feed rate is alternately switched between a forward feed period and a reverse feed period. Provided is an arc welding control method that switches a feed rate Fw for welding wire alternately between a forward feed period and a reverse feed period, repeats a short period and an arc period, and electrifies with a welding current Iw switched to a small current value in the latter half of the arc period, wherein a basic voltage setting value is set according to an average feed rate setting value, the error amplitude value for a voltage setting value and the basic voltage setting value is calculated, and the timing (current reduction time Td) for switching the welding current Iw to the small current value is varied on the basis of the average feed rate setting value and the error amplitude value.

The invention relates to a welding process with a consumable welding wire (5), in particular a cold metal transfer (CMT) welding process for build-up welding, and also to a welding apparatus (1) for carrying out such a welding process. According to the invention, during the welding process a preset melt-off efficiency (Ab) of the welding wire (5) is kept substantially constant, by the average wire feed (v.sub.mean) of the welding wire (5) being controlled, wherein the latest wire feed (v(t)) is measured, the average measured wire feed (v.sub.mean) is compared with a specified average wire feed (v.sub.soll_mean) corresponding to the desired melt-off efficiency (Ab), and in accordance with the deviation (Δv) of the average measured wire feed (v.sub.mean) from the specified average wire feed (v.sub.soll_mean) as control deviation, the welding current (I), the free wire length of the welding wire (5), the distance of the contact tube of the welding torch from the workpiece (CTWD Contact Tip to Work Distance) and/or the inclination angle of the welding torch (4) are changed as welding parameters (P.sub.i).

A system and method for controlling the position of a filler wire and/or a laser head, or other heating head, in a welding system. The distal end of the filler wire is gradually moved, e.g., upward, until electrical continuity with the weld pool is lost; the filler wire is then moved back into contact with the weld pool. The heating head may be stationary relative to the weld pool, or it may move, with the distal end of the filler wire, relative to the weld pool.

A welding system can manage wire feeders such that unused wire feeders are conveniently stowed. The welding system include two or more wire feeders individually attachable to a welding torch. The welding system includes one or more mount points to secure unused wire feeders and enable convenient swapping of an active wire feeder.