Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding assembly for a 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 cooling body configured to transfer heat from at least the first contact tip to coolant and to conduct the welding current.

Systems, methods, and apparatus to preheat welding wire are disclosed. An example welding assembly for a 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 cooling body configured to transfer heat from at least the first contact tip to coolant and to conduct the welding current.

A contact tip assembly having an electric contact unit containing a contact tip with an electric energy source, where the electric contact unit is positioned at a distance away from the outlet opening of a guide.

Systems, methods, and apparatus to preheat weld wire are disclosed. An example contact tip includes: an inner bore configured to conduct current to a consumable welding electrode; screw threads on an exterior of the contact tip; and a head opposite the screw threads on an exterior of the contact tip to enable threading and dethreading of the contact tip.

Systems, methods, and apparatus to preheat weld wire are disclosed. An example contact tip includes: an inner bore configured to conduct current to a consumable welding electrode; screw threads on an exterior of the contact tip; and a head opposite the screw threads on an exterior of the contact tip to enable threading and dethreading of the contact tip.

A welding torch for arc welding in a shielding gas atmosphere, includes: a contact tip for feeding a welding wire; a suction nozzle surrounding the welding wire, and sucking a gas from a space between the suction nozzle and the welding wire; and a shielding gas supply nozzle provided on the outer periphery of the suction nozzle, and supplying the shielding gas toward a welded portion from a space between the shielding gas supply nozzle and the suction nozzle. The welding torch satisfies “7≤Ltk≤17 and 0≤Lts≤18”, where Lts [mm] is a distance between the tip of the contact tip and the tip of the shielding gas supply nozzle, and Ltk [mm] is a distance between the tip of the contact tip and the tip of the suction nozzle.

A welding torch for arc welding in a shielding gas atmosphere, includes: a contact tip for feeding a welding wire; a suction nozzle surrounding the welding wire, and sucking a gas from a space between the suction nozzle and the welding wire; and a shielding gas supply nozzle provided on the outer periphery of the suction nozzle, and supplying the shielding gas toward a welded portion from a space between the shielding gas supply nozzle and the suction nozzle. The welding torch satisfies “7≤Ltk≤17 and 0≤Lts≤18”, where Lts [mm] is a distance between the tip of the contact tip and the tip of the shielding gas supply nozzle, and Ltk [mm] is a distance between the tip of the contact tip and the tip of the suction nozzle.

A welding or additive manufacturing contact tip includes an electrically-conductive body extending from a proximal end of the body to a distal end of the body. The body forms a first bore terminating at a first exit orifice at a distal end face of the body, and a second bore terminating at a second exit orifice at the distal end face of the body. The first and second exit orifices are separated from each other by a distance configured to facilitate formation of a bridge droplet between a first wire electrode delivered through the first bore and a second wire electrode delivered through the second bore during a deposition operation.

A welding torch maintenance apparatus and a welding tip changer are described. The welding torch maintenance apparatus and the welding tip changing apparatus each comprise a first gripping means for fastening the welding torch/diffuser so that the nozzle/welding tip is aligned with the rotational axis, a second gripping means for holding the nozzle/welding tip, the second gripping means rotates about the rotational axis to remove the nozzle/welding tip, and moves along the rotational axis. A drive means is provided for rotating the second gripping means, and a lift system is provided for moving the second gripping along the rotational axis. The welding torch maintenance apparatus further includes a cleaning means which enters the nozzle at the distal end and cleans an interior of the nozzle.

A welding torch maintenance apparatus and a welding tip changer are described. The welding torch maintenance apparatus and the welding tip changing apparatus each comprise a first gripping means for fastening the welding torch/diffuser so that the nozzle/welding tip is aligned with the rotational axis, a second gripping means for holding the nozzle/welding tip, the second gripping means rotates about the rotational axis to remove the nozzle/welding tip, and moves along the rotational axis. A drive means is provided for rotating the second gripping means, and a lift system is provided for moving the second gripping along the rotational axis. The welding torch maintenance apparatus further includes a cleaning means which enters the nozzle at the distal end and cleans an interior of the nozzle.