Wire buffer systems that can buffer one or more wires are described. The wire buffer system can include a buffer tube. The buffer tube can include entry passages, exit passages, an outer cylinder, and an inner cylinder. The inner cylinder can be fixed in a position coaxial with the outer cylinder. Flexible wire guides can be coupled to the entry passage. The flexible wire guide can extend in a spiral around the inner cylinder and exit the buffer tube through the exit passage. The wire buffer systems can further include measurement systems. The measurement systems can include time-of-flight (TOF) sensors, linear rails, and carriages.

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.

Systems and methods are disclosed that provides a helical wire for use in welding applications. A torch can be adapted to form the helical wire from a straight wire and to provide the helical wire as a consumable electrode in a welding or cladding application. The helical wire can be, for example, solid, tubular, or seamless tubular. The torch concurrently forms the helical wire and provides welding current for the welding or cladding application.

The subject embodiments are directed to a system to allow an uninterrupted flow of a coil welding wire from one container to another container, the coil of welding wire including a coil top and a coil bottom. Each container includes at least one vertically extending side wall, a closed bottom, a top opening for removing the welding wire and a wire coil receiving cavity within the outer packaging for receiving the wire coil, the feeding end and the trailing end being positionable near the top opening. A wire retaining ring is disposed on the coil top in the container and another said container, the wire retaining ring includes a slot that extends radially from a center of the coil to allow the trailing end of the coil to be drawn at a location away from the center of the coil.

The invention described relates generally to a method and apparatus for improving existing bulk wire transfer methodologies and more particularly, to welding wire packages for use as an endless wire container such that the welding wire of multiple containers can be linked together to produce an uninterrupted flow of welding wire to a welding operation by employing a welding wire transfer guide, the guide having an outwardly-facing curvilinear groove, one end of said groove of said welding wire transfer guide positioned along a tangent line running between an outer diameter of the in-process coil of wire and an opposed end of said groove along a tangent line running between an inner diameter of the staged coil of welding wire. The apparatus further includes a magnetically positionable wire guide arm above at least two, preferably each bulk welding wire container.

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.

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 storage and feeding assembly for a wire to be fed to an apparatus having a drum suitable for storing the wire and extending about a drum axis between a resting base and an open upper end is provided. A wire handling device positioned between the drum and the apparatus is suitable for extracting the wire from the drum to feed the wire to the apparatus. A lid, placed above the drum and having an upper lid wall in which an outlet passage for the wire is provided, and a lid side wall define a lid volume. The wire handling device extends into the lid volume substantially coaxially to the drum axis.

A storage and feeding assembly for a wire to be fed to an apparatus having a drum suitable for storing the wire and extending about a drum axis between a resting base and an open upper end is provided. A wire handling device positioned between the drum and the apparatus is suitable for extracting the wire from the drum to feed the wire to the apparatus. A lid is placed above the drum and an outlet passage for the wire is provided at a top of the lid. The storage and feeding assembly has a spacer suitable for being positioned in a releasable manner between the upper end of the drum and the lid in such a way as to act as an extension for the drum.

A method providing a welding apparatus configured to supply a welding wire to a welding gun and a welding system implementing the same is described. The welding gun has a trigger and an opening where the welding wire extends when the trigger is activated. The method also has a computer with a user interface that includes an automatic wire retract program, the program dynamically adjusting the amount of welding wire retraction based at least upon one of the following: welding are current, welding wire size, welding wire speed and burnback time. The program monitors the welding gun and determines when the trigger is disabled. The program indicates when a first condition is satisfied and retracts the welding wire so the welding wire preferably does not extend (or minimally extendsor may be at least partially recessed within the tip) from the opening of the welding gun nozzle tip. The system and method also includes an ability to stop advancement or retraction of the wire to prevent damage.