In order to provide an improved method for producing metal structures which allows a high level of flexibility in respect of process speed of production, material composition of the metal structure, production accuracy, and the quality of the produced metal structure, according to the invention, a second metal additive is supplied to a welding point on a metal base material, which second metal additive is fused at least by a second electric arc produced between a second electrode and the metal base material in order to produce a second weld seam at the welding point, wherein different materials are used as the first metal additive and as the second metal additive, and wherein the first metal additive and the second metal additive are supplied to the welding point sequentially in time and are fused in the region of the welding point in whichever of the first and second electric arcs is burning, in order to form the three-dimensional metal structure.

The present invention includes a welding system that has at least two metal inert gas (MIG) welders configured to perform a cooperative pulsed MIG welding process. The welding system also includes at least one communications link connecting the at least two MIG welders to deliver at least one of subordination commands and superiority commands to either of the at least two MIG welders to synchronize the cooperative pulsed MIG welding process.

A tip-base metal distance control method is provided. In this method, actual welding currents are measured under a predetermined actual welding condition, and an average actual welding current under the actual welding condition is then calculated. From a reference-current storage table, an average welding current under a welding condition that corresponds to the actual welding condition is extracted, and the extracted current value is set as a reference current. The calculated average actual welding current is then compared with the reference current to obtain a comparison result. The position of a welding torch in an upward or a downward direction is then corrected based on the comparison result.

An electric arc welder for depositing weld metal along a groove between two edges of a metal workpiece. The welder comprises: a leading electrode driven toward a point in the groove by a first wire feeder operated at a first speed by a first motor with a speed control input and a tachometer derived first feedback signal, a trailing electrode driven toward the same point by a second wire feeder operated at a second speed by a second motor with a speed control input and a tachometer derived second feedback signal, a first power source directing a first current to flow through the leading electrode and a second power source causing a second current to flow through the trailing electrode with the current flow being in a series arc circuit. The second power source being grounded to the workpiece to modify the series arc current so ground current flows to the workpiece whereby the second current is generally equal to the first current minus the ground current.

A system and method of welding is provided where a first welding power supply provides a first welding waveform to a strip electrode for welding a work piece and a second welding power supply provides a second welding waveform to at least one curtain electrode for welding the work piece. The at least one curtain electrode is positioned adjacent to a side of said strip electrode during welding.

A system of coating a component or part of a vehicle, device, or an apparatus with an abrasive resistant material (ARM) in order to increase the component or part's life cycle. A welding system can be used to deposit ARM between a lead electrode and a trail electrode and also deposit ARM behind the trail electrode. The welding system can also be used to deposit ARM that includes a lead electrode depositing the steel material and a trailing electrode that delivers an alloying material.

A system and method of welding is provided where at least two welding electrodes are provided to and passed through a single orifice on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes.

A system and method of welding is provided where at least two welding electrodes are provided to and passed through a single orifice on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes.

A hybrid welding system that comprises a plasma welding unit (Plasma unit) and a MIG welding unit with a non-consumable electrode (cathode) and a consumable electrode, where the electrodes are positioned relative each other so that their respective axes form an angle so that arcs initiated from the electrodes intersect a workpiece plane to define an impingement point distance D. A gas shielding nozzle forms a confined space around the tips of the electrodes, accommodates and covers them and keeps the angle between them inside the confined space and impingement point distance D. The Plasma unit comprises thermal cooling means with a channel surrounding the cathode down to the nozzle and tip of the cathode and also the tip of the MIG electrode around the gas shielding nozzle. A heat absorbing fluid circulates inside the cooling channel, especially at the electrodes tips that concentrate the highest amount of heat at highest temperature. Electrically insulating porous ceramic cover and filler surround the cathode. Oval shaped magnetic horns control the distance D and prevent the electrical arcs of the two electrodes from deflecting from and brought closer to each other. This prevents disturbances in the melting pool and controls the deposition rate.