My invention is an improvement to a welding arc igniter. My invention periodically disables the arc igniter for one or more AC half-cycles. When the igniter skips an AC half-cycle, the welding arc may not ignite, so average weld heat is reduced. AC weld heat can be adjusted in real time, by varying the fraction of AC half-cycles that are skipped. AC polarity balance can be adjusted in real time, by preferentially skipping the electrode-positive or electrode-negative half-cycles.

An example welding-type power supply, includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output the welding-type power based on a voltage-controlled control loop; and in response to detecting an output voltage less than a threshold voltage: during a first state, control the voltage-controlled control loop based on a first value of a control parameter of the voltage-controlled control loop to increase a response rate of the voltage-controlled control loop; and during a second state following the first state, control the voltage-controlled control loop based on a second value of the control parameter, wherein the second value of the control parameter causes a reduction in energy output by the power conversion circuitry relative to the first state.

Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.

My invention is an improvement to a welding arc igniter. My invention periodically disables the arc igniter for one or more AC half-cycles.

When the igniter skips an AC half-cycle, the welding arc may not ignite, so average weld heat is reduced.

AC weld heat can be adjusted in real time, by varying the fraction of AC half-cycles that are skipped.

AC polarity balance can be adjusted in real time, by preferentially skipping the electrode-positive or electrode-negative half-cycles.

Methods and system of the present invention include hot-wire strip deposition system used in combination with a high heat source, where the system deposits a strip consumable into a molten puddle. During deposition the strip consumable is deposited at an angle relative to the workpiece surface and in some embodiments has a downforce applied to the consumable to maintain contact between the puddle and the consumable. The heating current for the consumable is turned off or greatly reduced when an arcing event is detected. In some embodiments the strip consumable can be curved to promote contact during the deposition process.

A welding power supply device includes an inverter for converting DC power into AC power outputted to a welding load, and a voltage circuit for superimposing a restriking voltage on an output to the welding load when the polarity of output current of the inverter switches. The voltage circuit includes a restriking capacitor charged with the restriking voltage, a charging circuit to charge the capacitor with the restriking voltage, and a discharging circuit to discharge the voltage in the capacitor. The charging circuit includes a DC power supply and a booster to boost DC voltage from the DC power supply. The charging circuit charges the restriking capacitor in first and second states. In the first state, the DC voltage from the DC power supply is directly applied to the restriking capacitor. In the second state, DC voltage boosted by the booster is applied to the restriking capacitor.

A welding-type system includes a welding torch comprising a contact tip to provide an electrode wire. A secondary contact in electrical contact with the electrode wire, the secondary contact located along a length of the electrode wire and before the contact tip. Each of the contact tip and the secondary contact are connected to a welding-type power source. A current limiting device coupling located between the welding-type power source and the secondary contact and configured to limit a current at the secondary contact.

Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.

A welding-type system includes a welding torch comprising a contact tip to provide an electrode wire. A secondary contact in electrical contact with the electrode wire, the secondary contact located along a length of the electrode wire and before the contact tip. Each of the contact tip and the secondary contact are connected to a welding-type power source. A current limiting device coupling located between the welding-type power source and the secondary contact and configured to limit a current at the secondary contact.

Systems and methods to provide welding-type arc starting and stabilization with reduced open circuit voltage are disclosed. An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; and control circuitry configured to: control the power conversion circuitry to output a voltage pulse at a first voltage; determine whether the power conversion circuitry outputs current during the voltage pulse; in response to determining that there is less than a threshold output current during the voltage pulse, control the power conversion circuitry to turn off an output or output a second voltage that is less than the first voltage; and in response to determining that the power conversion circuitry outputs at least the threshold output current during the voltage pulse, control the power conversion circuitry to output the welding-type power.