Provided are a systems and methods for continuously providing a metal wire to a welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy wire.

Disclosed welding-type systems and methods are directed to employing a wire feeder for feeding an electrode wire from a wire source in a welding system. The wire feeder includes one or more drive rolls to advance the electrode wire by contact force. In disclosed examples, a contact force on the wire from the drive rolls is adjustable. In some examples, the system includes a controller to receive a feedback signal corresponding to the contact force. The controller commands an actuator or other mechanism to adjust the contact force on the wire, such as by adjusting a position of the one or more drive rolls in response to the contact force falling outside a range of threshold contact force values.

In embodiments, a welding apparatus includes an automated wire feed mechanism to output wire at a wire feed rate, where the wire is to provide a welding arc to a weld site. The wire feed rate is based at least in part on selected power to be provided to the weld site. Additional embodiments are described and claimed.

A feed assist unit (1) includes a base portion (2) having a plurality of ribs (16a-d) on a lower surface (18) thereof. A dome portion (4) is connected to the base portion (2), and a rotating conduit portion (6) has a curved shape and is coupled to the dome portion (4). Each of the ribs (16a-d) has a first end (20) adjacent to the dome portion (4) and a second end (22) adjacent an associated side (14) of the base portion (2). The feed assist unit (1) has first and second central axes (A-A, B-B) oriented perpendicular to each other. First and third of the ribs (16a, 16c) are oriented parallel to the second central axis (B-B) and the second and fourth of the ribs (16b, 16d) can be oriented parallel to the first central axis (A-A). The first and third ribs (16a, 16c) are offset from the second central axis (B-B) by an offset length (OL) and the second and fourth ribs (16b, 16d) are offset from the first central axis (A-A) the offset length (OL).

A sensor system detects the level of weld wire in a supply drum used in a manual, automated, or robotic welding operation. The system includes a pair of sensors on the exterior of the drum and which illuminate a light in one color to indicate a sufficient supply of weld wire and then a second color to indicate a low or depleted level of weld wire within the drum. The sensor system will start and stop the welding operation, depending upon the level of weld wire within the drum. The system can also send a notification to a remote operator as to the level of wire in the drum.

An articulated welding boom is disclosed, the boom having two guide modules above and below the primary swivel joint. The swivel joint itself is insulated from wire used to weld to prevent unwanted arcing. A wire feeder is mounted at an end of the secondary arm. Flexible wire conduit connects the guide module and the wire feeder, and the secondary arm folds down so that the operator can load or unjam the feeder without a ladder or lift.

A wire feeding system comprises a wire container including a box having an open upper side, and a wire container lid closing the upper side. The wire container lid includes a front wall having an opening through which wire is to be paid off. A wire outlet guide is attached to the front wall. The wire outlet guide comprises an upper and a lower hole for receiving the wire, the upper and lower holes being defined by a lower ring wall and an upper ring wall, respectively, and being distanced from each other in a wire feeding direction. At least the lower ring wall limits sideward movement of the wire and allows contact with the wire. The holes have a fixed position relative to the front wall. A deflection space bridging the distance between the holes allows sideward deflection of the wire between the ring walls.

A wire feeding mechanism includes feeding rollers and a cushioning mechanism. The feeding rollers feed a wire, which is drawn from a wire supply source, along a predetermined feed path. The cushioning mechanism is arranged between the wire supply source and the feeding rollers. The wire has an intermediate portion that extends from the wire supply source to the feeding rollers. The cushioning mechanism applies tension to the intermediate portion while the length of the intermediate portion is changing.

A welding wire container has a base element, a plurality of walls which extend upwardly from the base element and circumscribe a space in which a coil of welding wire can be placed. A reinforcement post is arranged in each of the corners of the space. A spacing rod is provided between adjacent reinforcement posts.

A welding wire container has a base element, a plurality of walls which extend upwardly from the base element and circumscribe a space in which a coil of welding wire can be placed. A reinforcement post is arranged in each of the corners of the space. A spacing rod is provided between adjacent reinforcement posts.