A welding apparatus includes a welding torch mounted to a frame and electrically connectable in a source current path of a welding current source, and an electrically conductive return current roller rollably mounted to the frame a substantially fixed distance from the welding torch. The return current roller is electrically connectable in a return current path of the welding current source, and has a rim sized and shaped to roll in electrically conductive contact with an unwelded seam of a workpiece.

Present embodiments include an additive manufacturing tool configured to receive a metallic anchoring material and to supply a plurality of droplets to a part, wherein each droplet of the plurality of droplets comprises the metallic anchoring material and a mechanical oscillation system configured to mechanically oscillate a structural component of the additive manufacturing tool toward and away from the part, wherein the mechanical oscillation system comprises a motor, a cam coupled to the motor, and a piston coupled to the cam, wherein the piston is fixedly attached to the structural component.

The invention relates a torch body for thermal joining of at least one workpiece, in particular for arc welding or arc brazing, said torch body comprising a non-consumable electrode provided in the body, in particular a tungsten electrode, for generating an arc between the electrode and the workpiece. The torch body has an end nozzle, which is devoid of potential, for discharging a shielding gas flow from a gas outlet. A secondary flow channel is provided for dividing the shielding gas flow into a main gas flow and a secondary gas flow, the secondary gas flow annularly surrounding the main gas flow at the gas outlet.

An example system includes: a hand-held welding tool that is manually placed in a welding position, wherein the hand-held welding tool is configured to be activated to cause a contact tip or a welding heat source to automatically move from a first position and to second position during a welding operation, and wherein a welding arc is automatically and repeatedly turned off and on while the contact tip or the welding heat source moves from the first position to the second position to make a plurality of welds between the first position and the second position, wherein, as a travel speed decreases, a time period between each arc on time increases to make equally spaced welds.

A welding apparatus comprises support members adapted to support parts to be welded, a slit being defined between planes of the support members to expose the parts to be welded. A linear actuator unit having a carriage linearly displaceable along the slit. A welding unit is mounted to the carriage having a torch located substantially below the planes of the support members, and is adapted to be in proximity to the parts via the slit to transmit current to the parts to weld same.

A teaching system rewinds a welding wire in accordance with a detection that a tip of a welding wire contacts a teach subject, and feeds the welding wire in accordance of a non-detection that the tip of the welding wire contacts the teach subject. Furthermore, the teaching system, if a current protruding length of the welding wire is less than a predetermined length, moves a robot in a direction away from the teach subject, and, if the current protruding length is greater than the predetermined length, moves the robot in a direction closer to the teach subject. The teaching system, if a determination that the current protruding length is equal to the predetermined length, stops feeding and rewinding of the welding wire and stops the robot, and stores a stop position of the robot as a teaching position.

Hybrid manual and automated welding systems and methods are described. A hand-held welding tool is manually positioned to engage a workpiece. The hand-held welding tool includes a motion device that is configured to automatically move a contact tip or a welding heat source during a welding operation after a manual triggering. A welding arc is automatically and repeatedly turned off and on to make a string of overlapping and equally spaced spot welds while the contact tip or the welding heat source moves from the first position to the second position.

A weld overlay machine assembly includes a carriage to support a hinged index bar and a wire feed assembly. The index bar has an auto height control unit and an index assembly to locate the position of a weld torch relative to the index bar. The assembly is configured to adjust the index bar to interior contours of the vessel while applying a layer of overlay material to a surface therein. The assembly runs along a track in the interior of the vessel. The assembly is configured to transition from sides of the vessel to that of the top or bottom domes wherein the curve of the domes are perpendicular to that of the radial sides. This transition is done without the need to add or remove components to the assembly. This is accomplished by providing the pivoting of the index bar relative to the track.

A method for compensating teaching positions which includes: generating a compensation start point and a compensation end point in positions where each of a number of teaching positions is sandwiched between the compensation start point and the compensation end point in a direction crossing a welding path, the number of teaching positions being set along the welding path of a welding base material; detecting a profile of the welding base material along a detection path by performing touch sensing while a welding torch is being moved along the detection path from the generated compensation start point toward the generated compensation end point, a welding wire protruding from the welding torch; and compensating each of the teaching positions based on the detected profile.

A system for characterizing manual welding exercises and providing valuable training to welders that includes components for generating, capturing, and processing data. The data generating component further includes a fixture, workpiece, at least one calibration device having at least two point markers integral therewith, and a welding tool. The data capturing component further includes an imaging system for capturing images of the point markers and the data processing component is operative to receive information from the data capturing component and perform various position and orientation calculations.