| Patent application number | Description | Published |
|---|
| 20090321401 | Method and System to Increase Heat Input To a Weld During a Short-Circuit Arc Welding Process - A method and a system to increase heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. A cycle of the electric welding waveform includes a pinch current phase providing an increasing pinch current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and a background current phase providing a background current level. At least one heat-increasing current pulse of the cycle is generated, providing a heat-increasing current level, during the background current phase, where the heat-increasing current level is above the background current level. The cycle of the electric welding waveform with the at least one heat-increasing current pulse may be repeated until the arc welding process is completed. | 12-31-2009 |
| 20090321402 | METHOD TO IMPROVE THE CHARACTERISTICS OF A ROOT PASS PIPE WELD - A method and a system for forming a root pass weld for a root pipe joint. A substantially periodic electric welding waveform is generated and a series of electric arc pulses are generated between an advancing welding electrode and a root pipe joint in response to the electric welding waveform. The electric welding waveform includes a base cycle having a background current phase providing a background current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and at least one heat-increasing current pulse during the background current phase providing a heat-increasing current level being above the background current level. | 12-31-2009 |
| 20100086702 | METHODS AND MATERIALS FOR LASER CLADDING - In a laser cladding, a diamond particulate is applied to the base material of an article that has been melted by an energy source such as a laser. The particulates are introduced into the molten material and allowed to settle as the article surface cools and solidifies. The diamond particulates function to increase the wear resistant characteristics of the article. In one embodiment, the diamond particulates are covered with a metallic veneer, which may be tungsten. | 04-08-2010 |
| 20100176104 | METHOD AND APPARATUS FOR ADAPTIVE GMAW SHORT CIRCUIT FREQUENCY CONTROL AND METHOD OF HIGH DEPOSITION ARC WELDING - An electric arc welding device for performing a pulse welding process by a current between an advancing electrode and workpiece where the welder comprises a short detecting circuit for creating a short signal upon occurrence of a short circuit between the advancing electrode and the workpiece and a boost circuit to create a plasma boost pulse after the short circuit is cleared during the time period when the welder is not outputting the peak pulse current. The peak pulse current to background current ratio is high and the duration of the peak pulse is short. | 07-15-2010 |
| 20100176109 | METHOD AND SYSTEM TO START AND USE A COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE - A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other. | 07-15-2010 |
| 20100213179 | WELDING METHODS AND SYSTEMS - A welding system is provided, in which two electrodes are directed at a joint between two work pieces and the electrodes are energized with DC pulse or AC welding waveforms at a controlled waveform phase angle. The systems include a synchronizing controller to synchronize the welding waveforms, and a work point allocation system provides one or more work point values to the welding machines to provide synergic control of the welding according to a user selected system work point value or parameter. The systems and methods further provide for synchronized work point value modulation for the opposite sides of a dual fillet weld. The system and method further provide a high energy heat source that directs intense heat at a portion of the weld joint to improve weld penetration. | 08-26-2010 |
| 20100326963 | WELDING DEVICE AND METHOD - A welding device includes an electrode head adapted to concurrently house an array of associated multiple, continuous-feed electrodes in a spaced apart configuration for concurrently depositing cladding material on the surface of a workpiece. The electrode head may be actuatable through a welding trajectory. The welding device may also include a welding power source adapted to provide power for simultaneously establishing a welding arc between each of the multiple, continuous-feed electrodes and the workpiece. | 12-30-2010 |
| 20110108527 | METHOD OF ARC WELDING ROOT PASS - A method for root pass welding steel plate and pipe is provided that uses pulse arc welding having a current pulse waveform exhibiting a low constant background current and fixed frequency. The welding process may be performed without a backer or backing material. | 05-12-2011 |
| 20110297658 | METHOD AND SYSTEM TO START AND USE COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE FOR WELDING - A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle. | 12-08-2011 |
| 20120097655 | METHOD TO CONTROL AN ARC WELDING SYSTEM TO REDUCE SPATTER - An electric arc welder and a method for performing a pulse welding process producing reduced spatter. The welder produces a current between an advancing electrode and a workpiece. The welder includes a short-detecting capability for detecting a short condition upon occurrence of a short circuit between the advancing electrode and the workpiece. The welder may also include a switching module in the welding circuit path of the welder having an electrical switch and a resistive path. Times of occurrence of short intervals can be tracked and a blanking signal can be generated based on the tracked short intervals to anticipate a next short interval in a next pulse period of the pulsed welding process. The blanking signal can be used to reduce a welding current in the welding circuit path by introducing additional resistance into the welding circuit path via the switching module, for example. | 04-26-2012 |
| 20120097656 | APPARATUS AND METHOD FOR PULSE WELDING WITH AC WAVEFORM - A pulse welding welder is provided which provides a pulse welding waveform to a workpiece to be welded. The welding waveform has a plurality of welding cycles and each of the cycles has a droplet transfer peak pulse and a background portion with a first polarity and an opposite polarity portion which precedes the droplet transfer peak pulse and is after the background portion. | 04-26-2012 |
| 20120273466 | METHOD AND APPARATUS FOR HEAVY PLATE JOINING WITH HYBRID LASER AND SUBMERGED-ARC WELDING PROCESS - A welding system and method is provided for welding heavy plate, where the method and device include using a laser which directs a beam to a first weld puddle to weld at least a portion of a work piece and a welding torch to direct a first welding electrode to the first weld puddle while the beam is being directed to the weld puddle. The welding torch deposits the first welding electrode to create a first weld bead. A flux nozzle is employed to deposit a welding flux onto the weld bead, and a submerged arc welding torch is used to direct a submerged arc filler metal to the weld bead to create a second weld bead through a submerged arc welding process, where the submerged arc welding process melts a portion of the first weld bead to consume the melted portion into the second weld bead. | 11-01-2012 |
| 20130015170 | METHOD AND SYSTEM TO INCREASE HEAT INPUT TO A WELD DURING A SHORT-CIRCUIT ARC WELDING PROCESS - A method and a system to control heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. The welding waveform has droplet transfer pulses and at least one heat input pulse which is generated during a background portion of the waveform. The at least one heat-increasing current pulse is above the background current level and has a polarity opposite of that of the droplet transfer pulse. | 01-17-2013 |
| 20130020289 | METHOD AND SYSTEM TO START AND STOP A HOT WIRE SYSTEM - A method and system to start and/or stop a hot wire process. A hot wire system includes a filler wire feeder that includes a contact tube for holding a filler wire, a wire feed mechanism, a power supply for applying a heating current to the wire; and a controller coupled to the feed mechanism and the power supply. The controller is configured for regulating the heating current to the wire and locating the wire with respect to the workpiece for forming a molten puddle with an arc to initiate a hot wire process. The controller may also be configured to regulate the feed of the wire to the molten puddle and one of regulate and/or pulse the current to the wire so as to retract the wire out of the molten puddle in a stable manner when stopping the hot wire process. | 01-24-2013 |
| 20130043219 | METHOD AND SYSTEM TO START AND USE COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE FOR WELDING - A method and system to weld or join workpieces employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle. | 02-21-2013 |
| 20130087543 | APPARATUS AND METHOD FOR POST WELD LASER RELEASE OF GAS BUILD UP IN A GMAW WELD - A system and method is provided where a work piece is welded at high speeds with minimal porosity and spatter. In embodiments, the work piece is welded with an arc welding process to create a weld puddle and the weld puddle is irradiated by a energy beam downstream of the arc welding operation, such that high welding speeds are attained. The high energy heat source is positioned downstream of the welding operation to input energy into the weld puddle to change its shape or characteristics to optimize bead shape and/or bead quality. | 04-11-2013 |
| 20130112675 | APPARATUS AND METHOD FOR SHORT CIRCUIT WELDING WITH AC WAVEFORM - A system and method is provided in which a surface tension transfer welding function is employed where the welding waveform switches polarity during welding when a short circuit event is detected. | 05-09-2013 |
| 20130119034 | METHOD TO IMPROVE GMAW AND GTAW WELDING PERFORMANCE - A method of controlling a power source includes providing a power supply module. The power supply module includes a first circuit that has at least one first switch. The first circuit is configured to provide a welding current to an electrode of a welding system. The power supply module also has a second circuit that includes a load that is operatively connected to at least one second switch. The second circuit is configured to provide the welding current to the electrode through the load. The method also includes controlling the at least one first switch such that the welding current flows through the at least one first switch and to the electrode during a ramp up portion of a welding waveform and such that no current flows through the at least one first switch during a ramp down portion of the welding waveform. The method further includes controlling the at least one second switch such that the welding current flows through the load and to the electrode during the ramp down portion of the welding waveform. The ramp down portion takes the welding current to a predetermined value. | 05-16-2013 |
| 20130146566 | METHOD AND SYSTEM TO LASER HOT WIRE LAYER A PIPE END - A system and method to clad a surface of a pipe using a high intensity energy source and a hot wire consumable, where the hot wire consumable is heated to a temperature sufficient to melt the consumable in a molten puddle while preventing the creation of an arc between the consumable and the puddle. | 06-13-2013 |
| 20130175247 | WELDER WITH POSITIONAL HEAT CONTROL AND METHOD OF USING SAME - An electric arc welder for producing a weave pattern across a workpiece with a succession of individual weld short runs or bead, each of which has a center portion extending between two transversely spaced edges. The welder comprising a power source, a wire feeder to direct a welding wire through a movable torch to the workpiece and a controller for creating a welding current between the wire and the workpiece. A mechanical device is used to move the torch along the bead and the controller has a program to perform a first weld process while the torch is moving along the center portion and a second weld process when the torch is adjacent the edges, where the first weld process has less heat input than the second weld process. | 07-11-2013 |
| 20130193124 | DUAL FILLET WELDING METHODS AND SYSTEMS - A system and method of hybrid welding a dual fillet weld. The system includes a laser system that leads a first torch and preheats at least one workpiece. The system also includes a first welding power supply that supplies a first welding waveform to a first wire via the first torch. The first welding waveform creates a first arc between the first wire and the at least one workpiece. The system further includes a second welding power supply that supplies a second welding waveform to a second wire via a second torch. The second welding waveform creates a second arc between the second wire and the at least one workpiece. A controller in the system is operatively coupled to the first power supply, the second power supply and the laser system. The controller synchronizes the first welding waveform and the second welding waveform such that welding current pulses of the second welding waveform at the second torch are not in phase with welding current pulses of the first welding waveform at the first torch. The system is set up such that the first arc and the second arc are across from each other on opposite sides of a weld. | 08-01-2013 |
| 20130213942 | METHOD AND SYSTEM FOR LASER WELDING AND CLADDING WITH MULTIPLE CONSUMABLES - A system and method to provide a welding or cladding operation is provided which using multiple consumables in a single operation, where the overall heat input is reduced. Each of the consumables can be deposited into a single molten puddle, where the total energy input to the puddle from trailing consumables is less than that of a leading consumable. Further embodiments can use more than one molten puddle, but the energy input by the leading consumable is still higher than that of trailing consumables. | 08-22-2013 |
| 20130213948 | METHOD AND SYSTEM TO INCREASE HEAT INPUT TO A WELD DURING A SHORT-CIRCUIT ARC WELDING PROCESS - A method and a system to increase heat input to a weld during an arc welding process. A series of electric arc pulses are generated between an advancing welding electrode and a metal workpiece using an electric arc welding system capable of generating an electric welding waveform to produce the electric arc pulses. A cycle of the electric welding waveform includes a pinch current phase providing an increasing pinch current level, a peak current phase providing a peak current level, a tail-out current phase providing a decreasing tail-out current level, and a background current phase providing a background current level. At least one heat-increasing current pulse of the cycle is generated, providing a heat-increasing current level, during the background current phase, where the heat-increasing current level is above the background current level. The cycle of the electric welding waveform with the at least one heat-increasing current pulse may be repeated until the arc welding process is completed. | 08-22-2013 |
| 20130228555 | SYNCHRONIZED HYBRID GAS METAL ARC WELDING WITH TIG/PLASMA WELDING - A system and method is provided in which each of a GMAW power supply and a TIG/plasma power supply are utilized in a common weld joint, where the waveforms from each of the power supplies are pulsed waveform which are pulsed out of phase which each other. Such a system minimizes arc interference and arc blow while at the same time increasing travel speed and throughput of a welding operation. | 09-05-2013 |
| 20130256288 | SYNCHRONIZED MAGNETIC ARC STEERING AND WELDING - A system and method of welding is provided where a pulse welding power supply is coupled with a magnetic field power supply such that a magnetic field can be generated proximate to a welding arc during pulse welding. During pulse welding a magnetic field is used to direct the welding arc and a droplet being transferred in the arc. | 10-03-2013 |
| 20130327749 | METHOD AND SYSTEM TO START AND USE COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE FOR WELDING ALUMINUM TO STEEL - A method and system to weld or join workpieces of different materials employing a high intensity energy source to create a weld puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle. | 12-12-2013 |
| 20140008342 | APPARATUS AND METHOD FOR ENERGY REPLACEMENT IN A WELDING WAVEFORM DURING WELDING - A system and method is provided which uses a power supply which receives an input signal and provides an output signal to an electrode, where the output signal generates an arc between the electrode and at least one workpiece, and the output signal has a desired output power profile. The power supply has at least an output power circuit which determines an output power of the output signal, a power differential calculator which determines a difference between the determined output power and the desired output power profile, and a waveform generator which changes a power output of the output signal based on the determined difference between the desired output power profile and the determined output power. | 01-09-2014 |
| 20140021182 | APPARATUS AND METHOD FOR MODULATING HEAT INPUT DURING WELDING - A system and method is provided in which a welding system modulates the heat input into a weld joint during welding by changing between a high heat input welding waveform and a low heat input welding waveform. The system can utilize detected weld joint geometry and thickness to vary the utilization of the high heat and low heat waveform portions to change the weld bead profile during welding. Additionally, the wire feed speed is changed with the changes between the high heat input and low heat input portions of the welding waveform. | 01-23-2014 |
| 20140021183 | METHOD AND SYSTEM FOR GAS METAL ARC WELDING AND A CONTACT TIP USED FOR THE SAME - A method and system with a welding torch having a contact tip which has an upper portion and a lower portion, where the upper portion and the lower portion are electrically isolated from each other and each of the upper portion and the lower portion make contact with the same electrode during a welding operation. A first power supply is coupled to the upper portion which provides a first current to the upper portion during the welding operation, and a second power supply is coupled to the second portion which provides a second current during the welding operation. The first and second currents are accumulated in the electrode during welding to provide a welding waveform. The first power supply can have a higher inductance than the second power supply. | 01-23-2014 |
| 20140042144 | FILLER WIRE FOR A LASER HOT WIRE SYSTEM - An extruded filler wire for use in a hot wire process. The filler wire includes a first core component; and a second coating component coupled to at least a portion of the first core component, the second coating component having a different composition from the first component, where the wire has a cross-sectional area with the first and second components asymmetrically arranged about a center of the wire. | 02-13-2014 |
| 20140076858 | CO2 GLOBULAR TRANSFER - The invention described herein generally pertains to a system and method for generating a negative polarity welding output current waveform to control a welding process. An electric arc welding system generates an electric welding waveform with portions in a negative polarity. A cycle of the electric welding waveform includes a background current phase, a short clearing ramp phase after the background current phase, a peak current phase, and a tail-out current phase of the electric welding waveform, wherein the peak current phase provides a negative peak current level, the tail-out current phase provides a monotonically increasing tail-out current level toward the positive background current level, and the short clearing ramp phase provides a decreasing current level in a positive polarity of current for the electric welding waveform. | 03-20-2014 |
| 20140083987 | SYSTEMS AND METHODS PROVIDING CONTROLLED AC ARC WELDING PROCESSES - Systems and methods for providing controlled AC arc welding processes. In arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from a consumable electrode to a workpiece and further aids in the maintaining or the re-establishing of an arc between the consumable electrode and the workpiece when a molten metal ball is transferred. | 03-27-2014 |
| 20140083988 | SYSTEMS AND METHODS PROVIDING CONTROLLED AC ARC WELDING PROCESSES - Systems and methods for providing controlled AC TIG arc welding processes is provided. In AC TIG arc welding power source embodiments, configurations of main and auxiliary bridge circuits allow for the directional switching of the output welding current through the welding output circuit path and selectively provide one or more high impedance paths to rapidly decay the arc current. The high impedance path aids in the low spatter transfer of molten metal balls from consumable to a workpiece, via an arc generated by a tungsten electrode, and further aids in the maintaining or the re-establishing of an arc between the tungsten electrode and the workpiece during welding. | 03-27-2014 |
| 20140091129 | SELF-LEVELING WELDING TRACTOR - A welding tractor is described as well as a process for using the tractor in which a predefined angle of inclination or declination is maintained during a circumferential welding process. | 04-03-2014 |
| 20140110385 | SYSTEM AND METHODS PROVIDING MODULATION SCHEMES FOR ACHIEVING A WELD BEAD APPEARANCE - Systems and methods for affecting an appearance of a deposited weld bead by modulating one or more welding parameters. For example, an electrode negative portion of a welding output current may be modulated to affect the appearance of a deposited weld bead. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with an electrode negative portion of a welding output current to affect a deposited weld bead appearance. Two or more welding processes may be interleaved with each other at a specified modulation frequency to affect a deposited weld bead appearance. One or more welding parameters may be modulated based on a welding travel speed to provide a consistent appearance of a deposited weld bead. | 04-24-2014 |
| 20140116994 | METHOD AND SYSTEM TO START AND USE A COMBINATION FILLER WIRE FEED AND HIGH INTENSITY ENERGY SOURCE - A method and system to start and use a combination wire feed and energy source system for any of brazing, cladding, building up, filling, and hard-facing overlaying applications. High intensity energy is applied onto a workpiece to heat the workpiece. One or more resistive filler wires are fed toward the workpiece at or just in front of the applied high intensity energy. Sensing of when a distal end of the one or more resistive filler wires makes contact with the workpiece at or near the applied high intensity energy is accomplished. Electric heating current to the one or more resistive filler wires is controlled based on whether or not the distal end of the one or more resistive filler wires is in contact with the workpiece. The applied high intensity energy and the one or more resistive filler wires are moved in a same direction along the workpiece in a fixed relation to each other. | 05-01-2014 |
| 20140124491 | METHOD AND SYSTEM TO CONTROL HEAT INPUT IN A WELDING OPERATION - A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on a desired welding temperature. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform. The desired welding temperature is one of a temperature setpoint and a temperature range. | 05-08-2014 |
| 20140124492 | METHOD AND SYSTEM TO CONTROL HEAT INPUT IN A WELDING OPERATION - A system for and method of controlling the heat input in a welding operation are provided. The system includes an arc welding power supply configured to output a welding waveform to a welding torch. The welding power supply includes a waveform generator to generate an output welding waveform. The power supply also includes a controller to optimize the output welding waveform based on one of a desired RMS voltage set point and a desired RMS voltage range. The optimization is performed by adjusting at least one of a power ratio and a duration ratio. The power ratio is a ratio of a power of a negative portion of the welding waveform to a power of a positive portion of the welding waveform, and the duration ratio is a ratio of a duration of a negative portion of the welding waveform to a duration of a positive portion of the welding waveform. | 05-08-2014 |
| 20140131320 | SYSTEM AND METHOD TO DETECT DROPLET DETACHMENT - The invention described herein generally pertains to a method for improved droplet detachment detection in a welding process in which a derivative of at least one welding parameter over time is used to detect droplet detachment from the wire during a welding operation based identification of a peak signature. | 05-15-2014 |
| 20140131321 | VOLTAGE SENSING FOR HOT WIRE GUNS - The invention described herein generally pertains to a system and method for a voltage sense lead being disposed on or within a welder gun in a hot wire application (e.g., hot wire laser, hot wire hybrid, and the like) to monitor voltage across the electrode. In this manner, resistive heating can be regulated to ensure that the wire and weld pool (e.g., puddle) temperature are within a desired range. The voltage sense lead can be incorporated into a welder gun or onto a welder gun in order to mitigate inaccuracies and voltage drops resultant of a cable connecting the welder gun to the wire feeder of a hot wire system. | 05-15-2014 |
| 20140131322 | SYSTEM AND METHODS PROVIDING MODULATION SCHEMES TO AFFECT HEAT INPUT TO A WELD - Systems and methods to affect heat input to a weld and, therefore, an appearance of a deposited weld bead by modulating a mixing ratio of shielding gases and/or one or more welding parameters. For example, a mixing ratio of two different shielding gases from two sources of shielding gases may be modulated to affect the appearance of a deposited weld bead. The modulation frequency may be based on a selected travel speed of a welding tool. Furthermore, a wire feed speed of a welding electrode may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. Other welding parameters may be synergistically modulated with the shielding gases to affect a deposited weld bead appearance. | 05-15-2014 |
| 20140131323 | HEAD ASSEMBLY FOR MULTI-WIRE SUBMERGED ARC WELDING (SAW) - The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can include a rectangular-shaped first contact bar and a rectangular-shaped second contact bar that can be affixed to one another with an assembly connective means in order to encase a plurality of electrodes therebetween. The second contact bar can include a set of grooves in which each groove can correspond to an electrode to provide guidance during a welding procedure. | 05-15-2014 |
| 20140251966 | INDUCTIVE DISCHARGE ARC RE-IGNITION AND STABILIZING CIRCUIT - A system and method for re-igniting and stabilizing an arc is provided. The system includes an output system that provides an output waveform, which includes a positive period and a negative period. The positive period includes a positive decay period prior to a transition to the negative period, and the negative period includes a negative decay period prior to a transition to said positive period. The system further includes an inductive discharge and stabilizing system, which includes at least one inductor. The at least one inductor re-ignites an arc between an electrode and a workpiece during the transition period from the positive period to the negative period and the transition period from the negative period to the positive period. The at least one inductor also provides a stabilizing current to stabilize said arc during at least a portion of said positive period and at least a portion of said negative period. | 09-11-2014 |
| 20140251967 | ARC WELDING WITH WAVEFORM CONTROL FUNCTION - A power supply with a waveform control function is provided. The power supply includes a waveform type selector that selects a desired shape for an output waveform and a setpoint selector that sets an output setpoint for the power supply. The power supply further includes a waveform generator that generates a reference waveform signal. The waveform generator includes a target generation circuit that generates a plurality of target values corresponding to the reference waveform signal. The waveform generator also includes a transition circuit that performs a series of transitions between the plurality of target values to generate the reference waveform signal, and a ramp circuit that controls a ramp speed of at least one transition of the series of transitions based on the desired shape. The generation of a target value corresponding to a peak value of the reference waveform signal is based on at least the output setpoint. | 09-11-2014 |
| 20140251968 | ARC WELDING WITH SYNCHRONIZED HIGH FREQUENCY ASSIST ARC INITIATION - A method of and system for controlling high frequency arc initiation in a power supply is provided. The power supply includes an output circuit that outputs at least one of a voltage waveform and a current waveform. High frequency, high voltage pulses are induced across a gap between an electrode and a workpiece to create an arc. The method and system further include monitoring at least one of a voltage reading and a current reading across the gap to determine a condition of the arc and controlling the high frequency, high voltage pulses based on the condition of the arc and the type of process, which can be, e.g., SMAW, GTAW, GMAW, FCAW, etc. | 09-11-2014 |
| 20140251971 | ELECTRIC ARC WELDER USING HIGH FREQUENCY PULSES AND NEGATIVE POLARITY - An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece, where the pulses and a background current defining a series of weld cycles. A wave shape generator defines the shape of the pulses and the background current including a controlled ramp up and/or ramp down in each of said cycles, and a circuit to change the shapes of the pulses and/or background current in a repeating pattern in each of the weld cycles, including a negative current in at one of said pulses. The shape change in a cycle can be between first and second shapes or by a rhythmic AC modulation. | 09-11-2014 |
| 20140263193 | CONSUMABLE AND METHOD AND SYSTEM TO UTILIZE CONSUMABLE IN A HOT-WIRE SYSTEM - A method and system to weld or overlay workpieces employing a high intensity energy source to create a puddle and at least one resistive filler wire which is heated to at or near its melting temperature and deposited into the weld puddle. The filler wire comprises a core and an electrically conductive outer matrix having particles to be deposited into the puddle. | 09-18-2014 |
| 20140263228 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. The system includes a first power supply that outputs a welding current that includes welding pulse currents and a background welding current. The system also includes a second power supply that outputs a heating current that includes first heating pulse currents at a first polarity and second heating pulse currents at an opposite polarity. The system also includes a controller that synchronizes at least one of the first heating pulse currents and the second heating pulse currents with at least one of the welding pulse currents and the background current to influence a position of an arc relative to a molten puddle based on magnetic fields created by the welding current and the heating current. | 09-18-2014 |
| 20140263229 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. The system includes a first power supply that outputs a welding current that includes welding pulse currents and a background welding current. The system also includes a second power supply that outputs a heating current that includes first heating pulse currents at a first polarity and second heating pulse currents at an opposite polarity. The system also includes a controller that synchronizes at least one of the first heating pulse currents and the second heating pulse currents with at least one of the welding pulse currents and the background current to influence a position of an arc relative to a molten puddle based on magnetic fields created by the welding current and the heating current. | 09-18-2014 |
| 20140263230 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. The system includes a first power supply that outputs a welding current that includes welding pulse currents and a background welding current. The system also includes a second power supply that outputs a heating current that includes first heating pulse currents at a first polarity and second heating pulse currents at an opposite polarity. The system also includes a controller that synchronizes at least one of the first heating pulse currents and the second heating pulse currents with at least one of the welding pulse currents and the background current to influence a position of an arc relative to a molten puddle based on magnetic fields created by the welding current and the heating current. | 09-18-2014 |
| 20140263231 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. The system includes a first power supply that outputs a welding current that includes welding pulse currents and a background welding current. The system also includes a second power supply that outputs a heating current that includes first heating pulse currents at a first polarity and second heating pulse currents at an opposite polarity. The system also includes a controller that synchronizes at least one of the first heating pulse currents and the second heating pulse currents with at least one of the welding pulse currents and the background current to influence a position of an arc relative to a molten puddle based on magnetic fields created by the welding current and the heating current. | 09-18-2014 |
| 20140263232 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. In some embodiments, the system includes a first power supply that outputs a first welding current. The first power supply provides the first welding current via a torch to a first wire to create an arc between the first wire and the workpiece. The system also includes a first wire feeder that feeds the first wire to the torch, and a second wire feeder that feeds a second wire to a contact tube. The system further includes a second power supply that outputs a heating current during a first mode of operation and a second welding current during a second mode of operation. The system also includes a controller that switches the second power supply from the first mode of operation to the second mode of operation to create a second (trailing) arc. | 09-18-2014 |
| 20140263233 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. In some embodiments, the system includes a first power supply that outputs a first welding current. The first power supply provides the first welding current via a torch to a first wire to create an arc between the first wire and the workpiece. The system also includes a first wire feeder that feeds the first wire to the torch, and a second wire feeder that feeds a second wire to a contact tube. The system further includes a second power supply that outputs a heating current during a first mode of operation and a second welding current during a second mode of operation. The system also includes a controller that switches the second power supply from the first mode of operation to the second mode of operation to create a second (trailing) arc. | 09-18-2014 |
| 20140263234 | TANDEM HOT-WIRE SYSTEMS - A system and method is provided. In some embodiments, the system includes a first power supply that outputs a first welding current. The first power supply provides the first welding current via a torch to a first wire to create an arc between the first wire and the workpiece. The system also includes a first wire feeder that feeds the first wire to the torch, and a second wire feeder that feeds a second wire to a contact tube. The system further includes a second power supply that outputs a heating current during a first mode of operation and a second welding current during a second mode of operation. The system also includes a controller that switches the second power supply from the first mode of operation to the second mode of operation to create a second (trailing) arc. | 09-18-2014 |
| 20140263237 | METHOD AND SYSTEM OF WELDING WITH A POWER SUPPLY HAVING A SINGLE WELDING MODE - A welding power supply and method are provided with a single welding mode in its controller such that the power supply can change from full DCEN output to AC output to a full DCEP output without having to change welding modes. | 09-18-2014 |
| 20140263239 | SYSTEM FOR AND METHOD OF NARROW-GROOVE JOINING OF METALS - A system and method is provided for narrow groove joining of metals. The method includes feeding a wire to a weld joint formed by the metals to be joined and transmitting a welding current through a length of the wire. The method also includes creating a molten puddle in the weld joint with the welding current. The method further includes performing a low heat transfer process on the wire for a predetermined low heat duration to transfer a first portion of the wire to the molten puddle, and performing a high heat transfer process on the wire for a predetermined high heat duration to transfer a second portion of the wire to the molten puddle. The low heat transfer process creates the molten puddle at a root of the weld joint. The high heat transfer process creates an arc that climbs sidewalls of the weld joint and the molten puddle follows the arc up the sidewalls to a top of the weld joint. | 09-18-2014 |
| 20140263241 | VARIABLE POLARITY PULSE WITH CONSTANT DROPLET SIZE - An electric arc welder including a high speed switching power supply with a controller for creating high frequency current pulses with negative polarity components through the gap between a workpiece and a welding wire advancing toward the workpiece. Molten metal droplets are quickly created during negative polarity portions of the weld cycle. Welding controls include integrating a parameter during the negative polarity portions to determine when a desired amount of energy has been generated at the welding wire. This energy is associated with a desired droplet size for consistent droplet transfers to the workpiece. | 09-18-2014 |
| 20140263242 | APPARATUS AND METHOD FOR WELDING WITH AC WAVEFORM - A welder power supply and welding method are provided which welds in a DCEN state, but when a short circuit is detected the current waveform switches to an EP state and the short circuit is cleared while the electrode has a positive polarity. | 09-18-2014 |
| 20140263533 | DRIVE ROLL ASSEMBLY - A wire feeder includes a wire feeder housing that encloses one or more drive roll assemblies rotatably connected with respect to the wire feeder housing for engaging welding wire. Each of drive roll assemblies includes a biasing element that adjusts compressive forces applied to the welding wire. | 09-18-2014 |
| 20140319112 | SYSTEMS AND METHODS TO FEED A WIRE WITHIN A WELDER - The invention includes a wire feed system that is used within a welder, the system having a forward drive roll that rotates in a first direction, a reverse drive roll that rotates in a second direction, which is opposite the first direction, wherein the forward drive roll and the reverse drive roll are both located on a first side of a wire, a first idle roll disposed opposite the forward drive roll, a second idle roll disposed opposite the reverse drive roll, wherein the first idle roll and the second idle roll are located on a second side of the wire, an arm that pivotally couples the first idle roll to the second idle roll, and an actuator that displaces the first idle roll to engage with the forward drive roll to advance the wire or displaces the second idle roll to engage with the reverse drive roll to retract the wire based upon a predetermined condition. | 10-30-2014 |
| 20140319113 | SYSTEMS AND METHODS TO FEED A WIRE WITHIN A WELDER - The subject embodiments relate to a retractable wire feed system used within a welder, which include a friction-drive system disposed on a first side of a wire, an idle drive roll located opposite the friction-drive system on a second side of a wire, wherein the friction-drive system advances the wire through a welding nozzle toward a workpiece, and a brake, which is applied to retract the wire when a predetermined condition is met. | 10-30-2014 |
| 20140339203 | METHODS AND SYSTEMS FOR MULTI-WIRE SURFACING - The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can house electrodes that allow deposition of material on a workpiece. At least a first set of electrodes and a second set of electrodes can be driven at different speeds. Moreover, welding arcs for one or more electrodes can be established based upon a predetermined order in which the predetermined order can be based on at least one of a location of the electrode head on the workpiece, a start of a welding process, and/or a stopping of a welding process. | 11-20-2014 |
| 20140374391 | SYSTEM AND METHOD FOR HOT WIRE TIG POSITIONED HEAT CONTROL - The invention described herein generally pertains to a system and method related to energizing a welding wire based on a location of an electrode at an edge on a workpiece. An edge detector can be configured to identify an edge on the workpiece during a welding operation and a controller can be configured to mange a temperature of a puddle formed by the electrode by adjusting one or more welding parameters. The welding parameters can be, but are not limited to, an energizing of the welding wire, a wire feed speed, a temperature of a high intensity heat source (e.g., arc, a sub arc, a tungsten inert gas (TIG) arc, a metal inert gas (MIG) arc, a laser, a plasma arc, a metal core, or a flux core), movement speed, among others | 12-25-2014 |
| 20150014283 | Hybrid Hot-Wire And Arc Welding Method And System Using Offset Positioning - A method and system to weld or join coated workpieces using an arc welding operation and at least one hot wire, resistance heated wire. Each of the arc welding and hot wire operation are directed to the same puddle. However, the arc welding operation is offset out of the joint from the hot wire operation, where the hot wire is directed into the joint. | 01-15-2015 |
| 20150028010 | SYSTEM AND METHOD OF CONTROLLING HEAT INPUT IN TANDEM HOT-WIRE APPLICATIONS - A system and method is provided. The system includes a high intensity energy source to create a molten puddle on a surface of a workpiece and a wire feeder that feeds a wire to the molten puddle via a contact tube. The system also includes a power supply that outputs a first heating current during a first mode of operation and a second heating current during a second mode of operation. The system further includes a controller that initiates the first mode of operation in the power supply to heat the wire to a desired temperature and switches the power supply from the first mode of operation to the second mode of operation to create a micro-arc. The second mode of operation provides at least one of an increased heat input to the molten puddle and an increased agitation of the molten puddle relative to the first mode of operation. | 01-29-2015 |
| 20150028011 | SYSTEM AND METHOD OF CONTROLLING HEAT INPUT IN TANDEM HOT-WIRE APPLICATIONS - A system and method is provided. The system includes a high intensity energy source to create a molten puddle on a surface of a workpiece and a wire feeder that feeds a wire to the molten puddle via a contact tube. The system also includes a power supply that outputs a first heating current during a first mode of operation and a second heating current during a second mode of operation. The system further includes a controller that initiates the first mode of operation in the power supply to heat the wire to a desired temperature and switches the power supply from the first mode of operation to the second mode of operation to create a micro-arc. The second mode of operation provides at least one of an increased heat input to the molten puddle and an increased agitation of the molten puddle relative to the first mode of operation. | 01-29-2015 |
| 20150028012 | SYSTEM AND METHOD OF CONTROLLING HEAT INPUT IN TANDEM HOT-WIRE APPLICATIONS - A system and method is provided. The system includes a high intensity energy source to create a molten puddle on a surface of a workpiece and a wire feeder that feeds a wire to the molten puddle via a contact tube. The system also includes a power supply that outputs a first heating current during a first mode of operation and a second heating current during a second mode of operation. The system further includes a controller that initiates the first mode of operation in the power supply to heat the wire to a desired temperature and switches the power supply from the first mode of operation to the second mode of operation to create a micro-arc. The second mode of operation provides at least one of an increased heat input to the molten puddle and an increased agitation of the molten puddle relative to the first mode of operation. | 01-29-2015 |
