An example welding-type power supply includes: power conversion circuitry configured to convert input power to welding-type power; a user interface configured to receive two or more inputs associated with corresponding qualitative characteristics of a welding arc created by the welding-type power, wherein the two or more inputs are defined within corresponding ranges of the respective qualitative characteristics; and control circuitry configured to: in response to a change in a first one of the two or more inputs, determine a corresponding change in a second one of the two or more inputs based on a relationship between the first and second ones of the two or more inputs; determine two or more welding-type parameters based on the two or more inputs; and control the power conversion circuitry based on the determined welding-type parameters.

A system and method of electric arc welding that includes a welding apparatus having an electric arc welder torch with sensors to determine the absolute position of the torch tip and the relative position of the torch tip to the weld joint during automatic welding. Combining absolute and relative positional data can be used to adjust the path of the robot during automated or robotic welding in response to variations in the weld joint.

A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

The present invention provides a unique and novel, low-cost external assembly that can be used to add a pulsed current functionality to a continuous welding machine. The external assembly is located in series between a pedal for controlling the welder and the welder itself. The external assembly includes a controller that modifies the pedal input signal typically entering directly into the welder. The modified signal converts the continuous welding machine such that it operates as a pulsed welding machine.

A welding system includes a consumable electrode, torch, wire feeder, and power supply. The power supply is configured to provide a plurality of waveforms to the torch to generate a welding current in the electrode. Each of the plurality of waveforms includes a pinch current portion followed by an arcing current portion, and the pinch current portion is preceded by a first arc suppression portion and the arcing current portion is followed by a second arc suppression portion. An arc exists between the electrode and a workpiece during the arcing current portion, and an air gap without an arc exists between the consumable electrode and the workpiece during the arc suppression portions. The power supply is configured to detect a short between the electrode and workpiece and generate the pinch current portion when the short is detected, and the wire feeder stops feeding the electrode when the short is detected and restarts feeding the electrode after the short is clear.

A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.

A method of hardfacing a metal component includes welding a surface area of the metal component using a Cold Metal Transfer (CMT) process. The method of hardfacing the metal component includes performing the CMT welding process in a weaving pattern over the surface area of the component. A consumable, low carbon steel wire electrode is used in the CMT process.

A three stage power source for an electric arc welding process comprising an input stage having an AC input and a first DC output signal; a second stage in the form of an unregulated DC to DC converter having an input connected to the first DC output signal and converts the first DC output signal to a second DC output signal of the second stage; and a third stage to convert the second DC output signal to a welding output for welding wherein the input stage and the second stage are assembled into a first module within a first housing structure and the third stage is assembled into a second module having a separate housing structure connectable to the first module with long power cables. The second module also includes wire feeding systems and electronics.

A method and apparatus for providing welding type power includes receiving input power and pulse width modulating a first forward converter and a second forward converter so that they operate as a pulse width modulated double forward converter to provide a welding type output. A phase relationship between the first forward converter and a second forward converter is selected from at least two available phase relationships using a controller. The controller includes a pwm module, and the pwm module includes a phase relationship module. The at least two available phase relationships are at least two of variable phase shifting, fixed phase staggering and locked in phase. The selected phase relationship is maintained over a predetermined range of outputs.

A method comprises: providing a welding current pulse through a welding circuit to create an arc for a welding operation; measuring an arc voltage to produce a measured arc voltage pulse that includes an inductive voltage drop due to inductance in the welding circuit and current ramps of the welding current pulse; and during the welding operation, implementing an inductance-compensation feedback loop. The feedback loop includes canceling the inductive voltage drop from the measured arc voltage pulse using a canceling voltage to produce a compensated arc voltage pulse; and deriving the canceling voltage based on the compensated arc voltage pulse.