Resistance spot rivet welding systems, subsystems, and methods of use thereof are provided.

The invention relates to an exchangeable wearing part of an arc welding torch, said wearing part being intended to be arranged in the region of an end, provided for carrying out a welding process, of the arc welding torch, wherein the wearing part is provided with a thread on an outer lateral surface and/or on a boundary wall of a recess, an improvement in heat transfer properties and, when such components are conducting, also improved power transmission properties are intended to be achievable. To this end, the invention proposes that, in the direction of a longitudinal axis of the wearing part, a first conical portion, having the thread provided for fastening the wearing part, of the lateral surface or of the boundary wall is followed, on the same lateral surface or boundary wall, by a thread-free second conical portion of the lateral surface or of the boundary wall.

The invention relates to an exchangeable wearing part of an arc welding torch, said wearing part being intended to be arranged in the region of an end, provided for carrying out a welding process, of the arc welding torch, wherein the wearing part is provided with a thread on an outer lateral surface and/or on a boundary wall of a recess, an improvement in heat transfer properties and, when such components are conducting, also improved power transmission properties are intended to be achievable. To this end, the invention proposes that, in the direction of a longitudinal axis of the wearing part, a first conical portion, having the thread provided for fastening the wearing part, of the lateral surface or of the boundary wall is followed, on the same lateral surface or boundary wall, by a thread-free second conical portion of the lateral surface or of the boundary wall.

A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

A wire feeder has a motor, mounting plate, intermediate mounting plate, and base assembly. The mounting plate has a plurality of mounting hole patterns and a shaft hole. The motor a mounting hole pattern that aligns with at least one of the plurality. One of a plurality of motor types can be mounted to the mounting plate. The mounting plate is mounted to the intermediate mounting plate, which is mounted to the base assembly. The base assembly includes a drive gear, which is connected to rotate with an insulating cap that receives a gear hub. The gear hub is connected to rotate with the motor shaft via matching keys. The insulating hub, intermediate mounting plate and mounting plate are electrically insulating, so that the base assembly is electrically isolated from the motor.

Approaches herein provide a torch handle including a pneumatically controlled jaw operable to engage an electrode. In one approach, a system is provided for distributing gas within the torch handle, the system including a pneumatic cylinder within a main housing of the torch handle. The pneumatic cylinder is coupled to a shaft for actuating first and second members of the jaw. The system further includes a gas passageway through the main housing, the gas passageway extending to an exit orifice disposed within the second member. A flow controller, including first and second valves, is operable to direct a flow of a gas to either the pneumatic cylinder or the gas passageway. In one approach, the first member is actuated towards the second member when the gas is directed through the gas passageway, and actuated away from the second member when the gas is directed to the pneumatic cylinder.

Approaches herein provide a torch handle including a pneumatically controlled jaw operable to engage an electrode. In one approach, a system is provided for distributing gas within the torch handle, the system including a pneumatic cylinder within a main housing of the torch handle. The pneumatic cylinder is coupled to a shaft for actuating first and second members of the jaw. The system further includes a gas passageway through the main housing, the gas passageway extending to an exit orifice disposed within the second member. A flow controller, including first and second valves, is operable to direct a flow of a gas to either the pneumatic cylinder or the gas passageway. In one approach, the first member is actuated towards the second member when the gas is directed through the gas passageway, and actuated away from the second member when the gas is directed to the pneumatic cylinder.

The disclosure concerns a method for monitoring and/or controlling a quality of spot weldings of a processing island, comprising at least two welding controls on one or more workpieces, wherein the method is based on a comparing of the measured values and an outputting of a fault message taking place from a central control of the processing island, the central control being in communicating connection with every welding control, in order to control them appropriately in dependence on all of the measured values and the predefined tolerance margin, the welding controls being in communicating connection with one another.

A welding electrode apparatus has an electrode base, and electrode tip, and a locking ring that clamps the tip to the base, and that, when released, permits the tip to be replaced when worn. The locking ring and electrode tip co-operate to define an accommodation for a machine fed nut. The locking ring has a non-electrically conductive end face, and stands proud of the tip of the electrode. The locking ring has an unobstructed outside peripheral face suitable for gripping and tightening or loosening with a wrench. The locking ring has an internal, annular fluid cooling gallery and inlet and outlet ports tapped into the gallery. The cross-section of the gallery is non circular. The wall thickness of the part is roughly constant. On assembly and installation, the locking ring clamps to the tip and base, and provides a thermal conduction heat path to each of them.

An arc welding apparatus and corresponding method includes a torch, a non-consumable electrode and a consumable electrode both disposed within the torch, a wire feeder configured to feed the consumable electrode in a vicinity of the non-consumable electrode, a first power source and a second power source that provide independent current, respectively, to the non-consumable electrode and the consumable electrode, and a weld process controller to control outputs of the first power source and the second power source such that a concentrated arc is formed, as a heat source, between the non-consumable electrode and a workpiece, and an inter-electrode arc is formed between the consumable electrode and the non-consumable electrode to melt the consumable electrode. The approach is characterized by low heat input, low distortion, low spatter, and the relative high speed or high deposition of laser and laser-MIG hybrid and other forms of multi-wire/multi-electrode welding, cladding, and additive manufacturing.