Aluminum-magnesium alloys useful as welding wire and mechanical support are disclosed. The aluminum-magnesium alloys exhibit improved cold wire drawing performance. Grain refiners and methods of forming the aluminum-magnesium alloys are further disclosed.

A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip, and a principal distance from the at least one aperture to the distal end face is varied to adjust the flow of the shield gas for improved cooling.

A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip, and a principal distance from the at least one aperture to the distal end face is varied to adjust the flow of the shield gas for improved cooling.

A metal-cored electrode for welding to form a weld bead on a ferrous material, which weld bead includes at least 35 wt. % nickel. The metal-cored electrode includes a metal sheath surrounding a core. The core includes greater than 35 wt. % nickel.

A metal-cored electrode for welding to form a weld bead on a ferrous material, which weld bead includes at least 35 wt. % nickel. The metal-cored electrode includes a metal sheath surrounding a core. The core includes greater than 35 wt. % nickel.

Systems and methods are provided for manually setting up a wire drive assembly of a welding power supply and automatically setting up welding power supply parameters. A drive roll is configured with multiple grooves for receiving multiple wires of different types and/or different diameters. A sensor can detect the configuration of the drive roll such as, for example, being configured to receive a particular wire type with a particular diameter in a particular groove, by detect a distance to the drive roll. The welding power supply can use this information to automatically set the wire speed.

Systems and methods are provided for manually setting up a wire drive assembly of a welding power supply and automatically setting up welding power supply parameters. A drive roll is configured with multiple grooves for receiving multiple wires of different types and/or different diameters. A sensor can detect the configuration of the drive roll such as, for example, being configured to receive a particular wire type with a particular diameter in a particular groove, by detect a distance to the drive roll. The welding power supply can use this information to automatically set the wire speed.

A method for preparing an automated welding method for a welding process moves a welding torch with a consumable welding wire during a movement phase at a positioning speed from an actual to a desired start position of a welding seam, and bridges the distance of the welding wire end from the workpiece during a creep phase. The creep phase is at least partially carried out during the movement phase. The wire is moved toward the workpiece at a first specified forward feed speed until a first wire end-workpiece contact is detected, moved away from the workpiece after first contact detection and then recurrently moved away from the workpiece, and the contact is interrupted again upon detection of further contacts, and the movement of the welding wire towards the workpiece and movement away from the workpiece after the contact is repeated until the start position is reached.

A method for preparing an automated welding method for a welding process moves a welding torch with a consumable welding wire during a movement phase at a positioning speed from an actual to a desired start position of a welding seam, and bridges the distance of the welding wire end from the workpiece during a creep phase. The creep phase is at least partially carried out during the movement phase. The wire is moved toward the workpiece at a first specified forward feed speed until a first wire end-workpiece contact is detected, moved away from the workpiece after first contact detection and then recurrently moved away from the workpiece, and the contact is interrupted again upon detection of further contacts, and the movement of the welding wire towards the workpiece and movement away from the workpiece after the contact is repeated until the start position is reached.

The invention uses the principle of the pneumatic turbine and a cooling system for the entire welding torch, wherein the gas used in the welding process, or even compressed air, enters through a conductor in the axial direction to the consumable, thus moving, a turbine, which in turn moves a tip and a tip holder. The welding torch can be used for extended periods of time at 100% cycle on welding machines of NEMA class I, since it is water cooled. In addition, the torch can be used in any welding source from any manufacturer, whether the machine is new or very old, as the euro standard (socket) is the same. This implies that there is no need to purchase a new welding machine, but only a torch. In construction and assembly environments, such as riser welding, refineries, joint welding, coating, and processes that aim to build a part using only one welding consumable, the use of said torch would bring a significant balance in terms of reduction of time and cost. This torch can also be used in any existing welding device, within the abovementioned processes.