A welding or additive manufacturing system includes a power supply having a controller which controls operation of the power supply. The power supply provides a current waveform to a contact tip assembly having a first bore terminating at a first exit orifice and a second bore terminating at a second exit orifice. The first exit orifice is configured to deliver a first wire electrode and said second exit orifice is configured to deliver a second wire electrode. The exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between the wire electrodes while preventing solid portions of the first wire electrode delivered through the first bore from contacting solid portions of the second wire electrode delivered through the second bore, during a deposition operation in which the current waveform is conducted to both of the wire electrodes simultaneously through the contact tip assembly.

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 3D printer can print a structure by depositing material into a weld pool that is moving relative to a workpiece. An electrode wire can supply energy to the weld pool while being fed at a first feed rate into the weld pool. A second wire can be fed into the weld pool at a second feed rate to deposit additional material and thereby speed up the overall material deposition rate. All of the energy in the weld pool may be supplied by the electrode wire. The printer can dynamically control the first feed rate and the second feed rate during printing. A mathematical model can be used to determine the second feed rate as a function of the first feed rate, the energy put into the weld pool, and the print head travel speed. The second feed rate may optimize the material deposition rate according to the model.

An electric arc welding system for depositing weld metal along a groove between two edges of a metal workpiece where the system contains a first power supply and a second power supply, each providing a welding waveform to respective welding electrodes. The positive output terminals of both power supplies are coupled to the same contact tip and the negative output terminal of one of the power supplies is not coupled to the workpiece.

A welding rod dispenser comprising: a deck, where the deck angles downward from back to front; a rotating assembly located at the front of the deck, where the rotating assembly comprises grabber teeth; and a leveler assembly located atop the deck. Welding rods placed atop the deck may tend to slide forward under the leveler assembly where the leveler assembly levels them into a single layer. Individual welding rods may then be grabbed by the grabber teeth one at a time before being moved forward by the rotating assembly for retrieval by the user.

A a multiple welding method having an improved starting process in which the control unit of the guide electrode starts welding-wire advancing of the guide electrode and sends a synchronization signal to the control unit of the trailing electrode when the guide electrode has moved a certain distance or for a certain time. The control unit of the trailing electrode starts welding-wire advancing of the trailing electrode in dependence on the received synchronization signal before the guide electrode touches the workpiece.

Described herein are examples of torch tracking systems that monitor travel directions, speeds, and/or distances of welding torches using retractable cords. In some examples, the torch tracking systems use a sensor to measure a speed at which a reel extends and/or retracts a cord, and/or measure a length of the cord that is extended and/or retracted. The reel or cord can be attached to some portion of the welding torch, such that movement of the torch away from the reel causes the reel to extend more cord, and movement towards the reel allows a spring loaded spool of the reel to automatically retract the cord. While reel based torch tracking systems may provide coarser tracking than the more complex and/or expensive torch tracking solutions, their simplicity and low cost may make them an attractive alternative.

A welding method materially cohesively bonding at least two components using at least one additive material. A welding seam is produced with a seam course between a seam start and a seam end. The process is controlled using at least one control unit, at least one external physical welding seam property of the welding seam is influenced by a control parameter of the control unit, and information is included in the control parameter. The information, during the process is stored in the welding seam between a start point and an end point in the seam course using the at least one external physical welding seam property so that the information can be read, optically and/or haptically, from a sequence of the at least one detectable external physical welding seam property along the course of the seam in the region between the start point and the end point.

A welding device (1) has a contact tip (2) with an elongated feeding means for feeding a welding wire (4), wherein the contact tip (2) is arranged on or in a nozzle holder (6). A feed device (100) transfers the welding wire (4) from a first orientation into a second orientation, wherein in the first orientation the welding wire (4) is fed to the feed device (100), and in the second orientation the welding wire (4) is led out of the feed device (100) to the nozzle holder (6). A plurality of welding wire cores (8, 10) are introduced into a conduit element (200) via a first conduit element end (202). The welding wire (4) which is guided in the welding wire cores (8, 10) can be guided out of the conduit element (200) via a second conduit element end (204). The welding wire (4) which is guided out of the conduit element (200) via the second conduit element end (204) can be fed into the feed device (100), especially while in the first orientation.

The present application relates to an arc welding arrangement and an electric arc welding method to be used with the arc welding arrangement. The arc welding arrangement comprising a first power source, a first electrode connected to say first power source, and a second electrode, said first electrode being adapted to generate a weld pool via a first electric arc present within a first arc region. The second electrode is operated at welding parameters adapted to ensure that excess energy from at least said first electrode is required to maintain said second arc ignited. The method comprises the step of feeding said second electrode so that it is allowed to consume excess energy from said first electrode to maintain said second arc ignited.