A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.

A welding system includes power conversion circuitry configured to convert input power to weld power and a first housing surface. The first housing surface includes a first mating geometry configured to mate with a first complementary geometry of a first modular surface of a first modular component of the welding system.

The wire feed mechanism includes a feed roll, a pressure roll, a pressure arm, and a pressure mechanism. The feed roll rotates around a rotation axis. The pressure roll is displaceable relative to the feed roll. The pressure arm has a first end and a second end that are separate from each other, and rotatably supports the pressure roll. The pressure mechanism engages with the pressure arm so that a pressure force is applied from the pressure roll to the feed roll with a wire held between the feed roll and the pressure roll. A force-receiving portion is provided at an end of the pressure arm. When the pressure roll presses the feed roll, the pressure mechanism applies a force to the force-receiving portion in a direction that is substantially parallel to the direction in which the wire is fed.

The wire feed mechanism includes a feed roll, a pressure roll, a pressure arm, and a pressure mechanism. The feed roll rotates around a rotation axis. The pressure roll is displaceable relative to the feed roll. The pressure arm has a first end and a second end that are separate from each other, and rotatably supports the pressure roll. The pressure mechanism engages with the pressure arm so that a pressure force is applied from the pressure roll to the feed roll with a wire held between the feed roll and the pressure roll. A force-receiving portion is provided at an end of the pressure arm. When the pressure roll presses the feed roll, the pressure mechanism applies a force to the force-receiving portion in a direction that is substantially parallel to the direction in which the wire is fed.

Provided are a systems and methods for continuously providing a metal wire to a welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy wire.

Provided are a systems and methods for continuously providing a metal wire to a welding torch for manufacturing objects by solid freeform fabrication to provide continuous deposition of metal to the freeform object, especially objects made with titanium or titanium alloy wire.

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 metal-cored electrode for welding to form a weld bead on a ferrous material, which weld bead includes at least 35 wt. % nickel. The metal-cored electrode includes a metal sheath surrounding a core. The core includes greater than 35 wt. % nickel.

A metal-cored electrode for welding to form a weld bead on a ferrous material, which weld bead includes at least 35 wt. % nickel. The metal-cored electrode includes a metal sheath surrounding a core. The core includes greater than 35 wt. % nickel.

Systems and methods are provided for manually setting up a wire drive assembly of a welding power supply and automatically setting up welding power supply parameters. A drive roll is configured with multiple grooves for receiving multiple wires of different types and/or different diameters. A sensor can detect the configuration of the drive roll such as, for example, being configured to receive a particular wire type with a particular diameter in a particular groove, by detect a distance to the drive roll. The welding power supply can use this information to automatically set the wire speed.