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.

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 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.

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.

Welding is performed by alternately switching a pulse arc welding period (where welding is performed by forward feeding a welding wire by a rotation for the forward feeding of a push side feeding motor and a rotation for the forward feeding of the pull side feeding motor and feeding a peak current and a base current) and a short-circuiting transition arc welding period (welding is performed by forward/backward feeding the welding wire by the rotation for the forward feeding of the push side feeding motor and a rotation for the forward/backward feeding of the pull side feeding motor and feeding a short-circuiting current and an arc current). During the short-circuiting transition arc welding period, a forward feeding peak value Wsp and/or a backward feeding peak value Wrp of a pull feeding speed Fw are compensation-controlled based on a wire storage amount of an intermediate wire storage.

Welding is performed by alternately switching a pulse arc welding period (where welding is performed by forward feeding a welding wire by a rotation for the forward feeding of a push side feeding motor and a rotation for the forward feeding of the pull side feeding motor and feeding a peak current and a base current) and a short-circuiting transition arc welding period (welding is performed by forward/backward feeding the welding wire by the rotation for the forward feeding of the push side feeding motor and a rotation for the forward/backward feeding of the pull side feeding motor and feeding a short-circuiting current and an arc current). During the short-circuiting transition arc welding period, a forward feeding peak value Wsp and/or a backward feeding peak value Wrp of a pull feeding speed Fw are compensation-controlled based on a wire storage amount of an intermediate wire storage.

A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

A welding or additive manufacturing system includes a contact tip assembly having first and second exit orifices. A wire feeder is configured to deliver a first and second wire electrodes through the exit orifices. An arc generation power supply is configured to output a current waveform to the wire electrodes simultaneously, through the contact tip assembly. The current waveform includes a bridging current portion, and a background current portion having a lower current level than the bridging current portion. The bridging current portion has a current level sufficient to form a bridge droplet between the wire electrodes before the bridge droplet is transferred to a molten puddle during a deposition operation. Solid portions of the wire electrodes do not contact each other during the deposition operation. The bridge droplet is transferred to the molten puddle during a short circuit event between the molten puddle and the wire electrodes.

The present disclosure provides a system for feeding a wire. The system may comprise a wire source configured to hold a wire. The system may comprise a driver roller configured to undergo rotation to direct the wire towards a wire receiver. The system may comprise a preload roller adjacent to the driver roller and configured to come in contact with the wire at a position adjacent to the driver roller. The preload roller and the driver roller may be separated by a gap. The size of the gap may be adjustable to permit the wire to be directed through the gap. The system may comprise an actuator coupled to the driver roller or the preload roller and configured to adjust the size of the gap. The system may comprise a controller operatively coupled to the actuator. The size of the gap may be adjusted by real-time closed-loop feedback.