An additive manufacturing system includes an energy source and a material delivery device. The energy source is configured to direct an energy beam toward a component to form a melt pool. The material delivery device is configured to feed a wire toward the melt pool to deposit material on the component. In some examples, the material delivery device is configured to discharge a current to the wire to disengage the wire from the melt pool. In some examples, the material delivery device is configured to measure an arc voltage between the wire and the component.

A gas, which flows between a welding device and work pieces while the work pieces are welded together, has large influence on the welding. A sensor device includes a sensor unit and a container that includes a housing case (i.e., housing portion) and a shielding member (i.e., shielding portion). The shielding member is attached to the housing case, and shields radiation heat directed toward the lower surface of the housing case among radiation heat generated while the work pieces W are welded together. The shielding member is inclined with respect to a flow direction of a gas passing through an outlet port for detection of a second gas flow channel so that the gas discharged from the outlet port for detection is blown to the shielding member and thus flows to a side opposite to the side where the work pieces W are to be welded together.

A method for producing an additively manufactured object includes melting and solidifying a filler metal to form weld beads and depositing the weld beads adjoining each other, thereby forming a weld-bead layer, and repeatedly depositing a next weld-bead layer on the formed weld-bead layer to conduct additive manufacturing. The method includes a bead formation step of forming a new weld bead so as to fill a recess formed by at least three of the already formed weld beads, in a cross-section perpendicular to a longitudinal direction of the weld beads.

A control system for regulating an additive manufacturing process of an additive manufacturing apparatus, the apparatus configured to add metal to a substrate by means of metal deposition. The apparatus comprises: a nozzle for output of a metal strip, the nozzle configured to be arranged at a distance from the substrate, and configured to move relative the substrate in XYZ-axes via a position actuator. The apparatus further comprises a heat source configured to melt the metal strip into a weld pool on the substrate, and an electrical power source configured to supply current via the metal strip 20 to the substrate. The control system is configured maintain process stability, during the deposition of a layer of metal, via: determining electrical conductance between the metal strip and the substrate by measuring at least one electrical property of the supplied current; determining the difference between the determined electrical conductance, and a desired electrical conductance; and, adjusting at least one of: the substrate to nozzle distance, the speed of the nozzle movement relative the substrate, the amount of supplied current, the heat provided by the heat source, and/or the rate of output of the metal strip, based on the difference between the determined conductance and the desired conductance.

A method controls a portable welding robot to ensure good bead appearance even where a workpiece corner and a curved section of a guide rail are not located on a concentric circle and where there is a large difference in curvature between the workpiece corner and the curved section of the guide rail. A portable welding robot sets a guide rail with respect to a workpiece having a corner and performs arc welding on the workpiece while moving on the guide rail and a welding control device controls the portable welding robot. The control method includes determining a torch position on the workpiece via a torch position determination unit, calculating a torch angle at the torch position via a torch angle calculation unit, and controlling the torch angle via a movable part based on the calculated torch angle.

The present invention is directed to a system and method of remotely controlling a welding machine with command signals transmitted to the welding power source across a weld cable connecting the power source to a remote device, such a wire feeder. A transmitter transmits the control commands containing desired welding operational parameters to a receiver disposed in the power source across a weld cable also designed to carry welding power from the power source to the wire feeder.

A welding system includes a welding power supply, wire feeder, and welding circuit connecting the power supply to the wire feeder. The power supply and the wire feeder are configured for bidirectional communication over the welding circuit. The power supply includes a voltage sensor that measures a voltage level, and a current sensor that measures a current level, on the welding circuit. The power supply is configured to operate in a first welding mode to output a power voltage level to the welding circuit to power the wire feeder in response to a communication from the wire feeder over the welding circuit. The power supply generates periodic voltage dip pulses on the welding circuit, and automatically switches to a second welding mode different from the first welding mode based on the voltage level on the welding circuit falling below a threshold voltage level during a voltage dip pulse.

A system for controlling multiple wire feed motors for use in a welding-type system including a push motor controlled to operate at a target wire feed speed and a pull motor disposed in a welding torch controlled to apply a target torque to the fed welding wire. Such a system eliminates shaving and bird nesting of welding wire.

A consumable assembly for use in an arc welding apparatus is provided that includes a nozzle assembly having a nozzle body, an insulator disposed within the nozzle body, and a nozzle insert disposed within the insulator. The nozzle insert includes an internal gas diverter. A contact tip is disposed within the nozzle assembly and includes at least one aperture extending from an exterior portion to an internal cavity, an exit orifice, a distal end face, and an exterior surface extending between the at least one aperture and the distal end portion of the contact tip. The internal gas diverter directs a flow of shield gas exiting the at least one aperture along the exterior surface of the contact tip, and a principal distance from the at least one aperture to the distal end face is varied to adjust the flow of the shield gas for improved cooling.

A method for preparing an automated welding method for a welding process moves a welding torch with a consumable welding wire during a movement phase at a positioning speed from an actual to a desired start position of a welding seam, and bridges the distance of the welding wire end from the workpiece during a creep phase. The creep phase is at least partially carried out during the movement phase. The wire is moved toward the workpiece at a first specified forward feed speed until a first wire end-workpiece contact is detected, moved away from the workpiece after first contact detection and then recurrently moved away from the workpiece, and the contact is interrupted again upon detection of further contacts, and the movement of the welding wire towards the workpiece and movement away from the workpiece after the contact is repeated until the start position is reached.