B23K9/28

Detection of contact tip consumption with welding

An embodiment includes a welding system for performing an automatic GMAW welding process. The welding system provides a welding contact tip configured to be attached to a welding tool. The contact tip is configured to accept a consumable welding wire electrode that is fed there-through during the automatic GMAW welding process to form an arc between a tip of the consumable welding wire electrode and a work piece. A secondary material, being of a different material from that of the welding contact tip, is positioned at or near a distal end of the welding contact tip. During the automatic GMAW welding process, detection of a flaring event of the arc by the welding system is facilitated by the secondary material changing phase in response to the flaring event, resulting in changing at least one detectable characteristic of the arc.