A welding or cladding apparatus in which one or more energy beam emitters are used to generate a wide beam spot transverse to a welding or cladding path, and one or more wide feeders feed wire to the spot to create a wide welding or cladding puddle.

A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

A method and system to manufacture workpieces employing a high intensity energy source to create a puddle and at least one resistively heated wire which is heated to at or near its melting temperature and deposited into the puddle as droplets.

The present disclosure is directed, in certain embodiments, a system for depositing material from a metal feedstock. The system includes a feedstock guide configured to guide a metal feedstock from a material feeder to extend beyond a terminal end of the feedstock guide. The system includes a ceramic collar disposed at the terminal end of the feedstock guide and configured to guide the metal feedstock extending from the terminal end of the feedstock guide to a deposition outlet of the ceramic collar. An induction coil disposed adjacent to the ceramic collar and configured to heat a portion of the metal feedstock within the ceramic collar, such that material of the metal feedstock can be deposited on a surface from the deposition end of the ceramic collar.

A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

Methods and system of the present invention include hot-wire welding system used in combination with arc welding systems, where the welding system initiates an arc clearing routine in hot-wire welding system. The arc clearing routine includes detection of an arc and then skipping a complete pulse of the hot-wire waveform and initiating the next pulse to determine is consumable separation still exists. Follow-on pulses are repeatedly initiated until it is determined that consumable separation does not exist, at which time the hot-wire operation is continued.

A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle.

A welding system and a method of control. The welding system may include a weld gun that may have an induction coil and a guide sleeve. The induction coil may heat a welding electrode in the weld gun. The guide sleeve may inhibit the welding electrode from engaging the induction coil.

A system for and a method of controlling a filler wire and/or an heat source is provided. The system includes a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of the at least one workpiece. A filler wire feeder is configured to feed a filler wire into said molten puddle, and a travel direction controller is configured to advance the high intensity energy source and the filler wire in a travel direction to deposit the filler wire on the at least one workpiece. The system also includes a controller configured to move the filler wire and/or the energy source in at least a first direction during the feeding and advancing of the filler wire. At least the first direction is controlled to obtain a desired shape, profile, height, size, or admixture of a bead formed by the molten puddle.

Systems, methods, and apparatus to preheat weld wire are disclosed. An example welding torch includes a first contact tip configured to conduct welding current to a consumable electrode, a second contact tip configured to conduct preheating current to the consumable electrode, and a plurality of liquid cooling assemblies configured to conduct the preheating current and to conduct the welding current to the consumable electrode.