A material processing system includes a power supply and a wire feeder to feed a wire electrode for a material processing operation. The enthalpy and/or temperature of a region of the tip of the electrode is maintained substantially constant via closed loop control. The control may be based upon regulation of current applied to the electrode. The control of the current may be based upon an electrode extension error. Wire feed speed may also be controlled to assist in maintaining a substantially constant enthalpy and/or temperature near the electrode tip.

Some examples of the present disclosure relate to welding torches having a thermal insulating plate (400). The thermal insulating plate is comprised of a thermally insulating material, and is positioned between a front housing (302) and a drive gearbox (324) of the welding torch. The front housing (302) is connected to a gooseneck that conducts electrical energy to a torch tip (i.e. front end) of the welding torch. The drive gearbox (324) includes a gear assembly configured to drive a drive roll that moves a wire electrode through the welding torch (e.g. toward the torch tip of the torch). The thermal insulating plate (400) acts as a heat dam to decrease and/or reduce thermal energy transfer from the torch tip of the welding torch (e.g. via the front housing) towards the rear of the welding torch (e.g. through the drive gearbox), where the thermal energy may heat the welding torch handle and/or damage some of the more expensive and/or sensitive components in the handle (e.g. a motor of the drive gearbox).

The invention relates a torch body for thermal joining of at least one workpiece, in particular for arc welding or arc brazing, said torch body comprising a non-consumable electrode provided in the body, in particular a tungsten electrode, for generating an arc between the electrode and the workpiece. The torch body has an end nozzle, which is devoid of potential, for discharging a shielding gas flow from a gas outlet. A secondary flow channel is provided for dividing the shielding gas flow into a main gas flow and a secondary gas flow, the secondary gas flow annularly surrounding the main gas flow at the gas outlet.

The invention relates a torch body for thermal joining of at least one workpiece, in particular for arc welding or arc brazing, said torch body comprising a non-consumable electrode provided in the body, in particular a tungsten electrode, for generating an arc between the electrode and the workpiece. The torch body has an end nozzle, which is devoid of potential, for discharging a shielding gas flow from a gas outlet. A secondary flow channel is provided for dividing the shielding gas flow into a main gas flow and a secondary gas flow, the secondary gas flow annularly surrounding the main gas flow at the gas outlet.

A welding torch for arc welding, comprising a holder for retaining a welding electrode and for transmitting electric current to the welding electrode, a neck attached to the holder for supporting the holder and for transmitting electric current to the holder and a handle attached to the neck at a distal end of the handle. The neck is arranged to be connected to a cable for transmitting electric current to the neck, the handle is arranged to be attached to the neck at a distal end of the handle, the handle is arranged to receive the cable inside the handle. The handle comprises a body made of flexible material, for allowing movement of the distal end of the handle in relation to a proximal end of the handle.

A welding torch for arc welding, comprising a holder for retaining a welding electrode and for transmitting electric current to the welding electrode, a neck attached to the holder for supporting the holder and for transmitting electric current to the holder and a handle attached to the neck at a distal end of the handle. The neck is arranged to be connected to a cable for transmitting electric current to the neck, the handle is arranged to be attached to the neck at a distal end of the handle, the handle is arranged to receive the cable inside the handle. The handle comprises a body made of flexible material, for allowing movement of the distal end of the handle in relation to a proximal end of the handle.

Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding torch includes: a welding assembly comprising: a first contact tip configured to conduct welding current to a consumable electrode; and a second contact tip configured to conduct preheating current to the consumable electrode; a neck having a bend, the neck configured to hold the welding assembly and to deliver the consumable electrode to the welding assembly; a torch body configured to hold the neck opposite the welding assembly; and a torch mounting assembly; wherein the welding assembly, the neck, the bend, the torch body, and the torch mounting assembly are dimensioned such that the welding torch provides a same tool center point distance, a same bend angle, and a same approach angle when used to replace a second welding torch having a single contact tip.

A welding system includes a power supply configured to output power to a welding device. The power supply is configured to alternate the power output between an arc phase and a hotwire phase. The power output in the arc phase produces an arc between a welding electrode and a workpiece, and the power output in the hotwire phase heats the welding electrode without producing an arc.

A welding system includes a power supply configured to output power to a welding device. The power supply is configured to alternate the power output between an arc phase and a hotwire phase. The power output in the arc phase produces an arc between a welding electrode and a workpiece, and the power output in the hotwire phase heats the welding electrode without producing an arc.

A welding system having a weld torch, a first transmitting circuit, and a first receiving circuit is provided. The weld torch is coupled to a weld cable and is configured for a welding application. The first transmitting circuit includes a first processor and a sensor system with at least one sensor configured to detect sensor information related to the weld torch. The first processor transmits one or more control signals based on the received sensor information. The first receiving circuit includes communications circuitry and a second processor that receives the one or more control signals and generates information related to a trigger status based on the one or more control signals. The communications circuitry transmits the information to the wire feeder, and the wire feeder controls an operating parameter of the welding system based at least in part on the information related to the trigger status.