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.

A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

In each of roller groups, multiple straightening rollers include a first roller, a second roller, . . . , an n-th roller in this order in a direction in which a welding wire passes through, and the n rollers (n is an integer of 4 or more) bend the welding wire alternately in opposite directions and straighten a curl of the welding wire. The n rollers are arranged such that an entrance wire deformation amount .sub.in calculated by using a numerical formula of .sub.in={2t(.sub.in+t)/ L.sub.in.sup.2}100 ranges from 0.6 to 1.0 (%), and an exit wire deformation amount tout calculated by using a numerical formula of .sub.out=2t(.sub.out+t)/L.sub.out.sup.2}100 ranges from 0.0 to 0.3 (%) . Diameters 2r of the multiple straightening rollers are 20 mm or less. An arrangement interval L of the multiple straightening rollers is 11.5 mm or more.

A wire conveying mechanism, preferably for a welding, cladding or additive manufacturing apparatus, with a slip clutch mechanism connectable to a motor. Such a wire conveying mechanism may include a wire feeder for feeding an electrode wire in a welding system having a drive roller assembly comprising a plurality of drive rollers to grip the electrode wire and to pull the electrode wire from an electrode wire source toward a conduit and a torque-managing device operatively coupled between a motor and the drive roller assembly, wherein the torque-managing device receives the rotational force from the first motor and regulates the first torque to output a second torque to the drive roller assembly.

A method of operating a welding torch using a rotating coupler assembly that operates between 0 and 800 amps. The rotating coupler assembly allows for 360 degrees of rotation while keeping rotational friction at a minimum. The breakaway torque for the rotating coupler assembly is insignificant and the rotating coupler assembly can be rotated with little effort by hand. While the rotating coupler assembly minimizes rotational friction the design allow for rotating coupler assembly to continue to operate after 1-5 mm of wear on the contact surfaces. An embodiment of the rotating coupler assembly can be quickly disconnected from the unicable.

A welding system includes a welding torch assembly including a body, a first feed roll, a second feed roll, and a lever. The first and second feed rolls are both configured to rotate with respect to the body, and the first and second feed rolls are disposed opposite from one another about a welding wire feed region. The lever is configured to pivot at a first end of the lever about a lever joint of the body, and the second feed roll is movable between a first position and a second position in response to movement of a second end of the lever. The second feed roll is adjacent to the first feed roll in the first position, the second feed roll is not adjacent to the first feed roll in the second position, and the lever is configured to maintain the feed roll in the second position.

A welding or additive manufacturing wire drive system includes a first drive roll and a second drive roll. One or both of the drive rolls has a circumferential groove for simultaneously driving both of a first wire electrode and a second wire electrode located between the drive rolls in the circumferential groove. A sensor device generates a signal or data corresponding to a consumed or remaining amount of one or both of the wire electrodes. The first wire electrode contacts the second wire electrode within the circumferential groove. The first wire electrode further contacts a first sidewall portion of the circumferential groove. The second wire electrode further contacts a second sidewall portion of the circumferential groove. Both of the wire electrodes are offset from a base portion of the circumferential groove, said base portion extending between the first sidewall portion and the second sidewall portion of the circumferential groove.

A consumable filler metal delivery system includes a reciprocating wire feeding gear assembly configured to move a wire forward and backward with a net forward motion and a motor configured to drive the reciprocating wire feeding gear assembly, wherein the motor is configured to rotate only in one direction during operation of the consumable filler metal delivery system.

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.

A rotating tool system attachment on the spindle of a computer numerical control (CNC) machine includes a rotating assembly mounted on a static assembly. The rotating assembly provides a continuous supply of a wire material for deposition on a substrate during an additive manufacturing process. The rotating assembly includes a material supply housing a feedstock of wire mounted on a rotating spindle and a wire feeder configured to draw the wire from the wire supply and provide the wire for application during the additive manufacturing process. The tool system can be attached to the spindle of CNC machine to provide additive manufacturing capabilities to the CNC machine.