A junction structure includes a first material that is a metallic material, a third material that is a metallic material and is weldable to the first material, and a second material which is a nonferrous metallic material or a nonmetallic material. The second material is sandwiched and fixed between the first material and the third material by lap joining. At least one of the first material or the third material has a weld zone where the first material and the third material are melted and joined together, and at least one exhaust groove or at least one exhaust hole around the weld zone. The at least one exhaust groove or the at least one exhaust hole penetrates a thickness of the at least one of the first material or the third material.

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.

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 MIG welding method for carbon steels using an Ar shielding gas. The method includes short-circuiting a welding wire and a base material. The average short-circuiting frequency in welding is 20 Hz to 300 Hz and the maximum short-circuiting period is 1.5 s or less.

A MIG welding method for carbon steels using an Ar shielding gas. The method includes short-circuiting a welding wire and a base material. The average short-circuiting frequency in welding is 20 Hz to 300 Hz and the maximum short-circuiting period is 1.5 s or less.

An orientation and guide mechanism for a welding system includes a pair of opposed guide members. A weld wire having a non-round cross-section is fed through a guide passageway formed between the guide members, each of which have recessed channels that combine to define the guide passageway. The guide passageway has a non-round shape corresponding to the non-round shape of the wire. The orientation mechanism and the guide members thereof is adjustable relative to a welding device of the weld system, such that the orientation of the wire can be controlled and maintained by adjusting the orientation mechanism. The wide side of the wire may be adjusted to be presented to a radiant energy source, and/or the non-round wire may be adjusted relative to the desired weld seam.

The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

The disclosed technology generally relates to consumable electrode wires and more particularly to consumable electrode wires having a core-shell structure, where the core comprises aluminum. In one aspect, a welding wire comprises a sheath having a steel composition and a core surrounded by the sheath. The core comprises aluminum (Al) at a concentration between about 3 weight % and about 20 weight % on the basis of the total weight of the welding wire, where Al is in an elemental form or is alloyed with a different metal element. The disclosed technology also relates to welding methods and systems adapted for using the aluminum-comprising electrode wires.

A flux-cored wire of the present disclosure has a steel sheath and a flux filled at an inside of the steel sheath, has a total amount of moisture by ratio with respect to a total wire mass of 300 ppm or less, has flux containing fluorides, and has an amount of the fluorides by ratio with respect to the total wire mass of, by total of values converted to F, 0.11 mass % or more and 2.50 mass % or less. If using the flux-cored wire of the present disclosure for welding, a stable weld shape can be obtained and, further, the amount of diffusible hydrogen of the weld metal can be reduced. For this reason, the flux-cored wire of the present disclosure can be suitably used for welding high strength steel such as ferrite steel.

A flux-cored wire of the present disclosure has a steel sheath and a flux filled at an inside of the steel sheath, has a total amount of moisture by ratio with respect to a total wire mass of 300 ppm or less, has flux containing fluorides, and has an amount of the fluorides by ratio with respect to the total wire mass of, by total of values converted to F, 0.11 mass % or more and 2.50 mass % or less. If using the flux-cored wire of the present disclosure for welding, a stable weld shape can be obtained and, further, the amount of diffusible hydrogen of the weld metal can be reduced. For this reason, the flux-cored wire of the present disclosure can be suitably used for welding high strength steel such as ferrite steel.