Abstract:
Systems and methods for facilitating the starting and stopping of arc welding processes, as well as for responding to events in mid-weld. Specially designed signals may be briefly applied between a welding electrode and a welding workpiece at the start and end of a welding process to gracefully and properly start and stop a weld. Furthermore, specially designed signals may be briefly applied in the middle of a welding process, if determined events occur, to counter the undesirable effects of the events.
Abstract:
An embodiment includes a welding system for performing an automatic GMAW welding process. The welding system provides a welding contact tip configured to be attached to a welding tool. The contact tip is configured to accept a consumable welding wire electrode that is fed there-through during the automatic GMAW welding process to form an arc between a tip of the consumable welding wire electrode and a work piece. A secondary material, being of a different material from that of the welding contact tip, is positioned at or near a distal end of the welding contact tip. During the automatic GMAW welding process, detection of a flaring event of the arc by the welding system is facilitated by the secondary material changing phase in response to the flaring event, resulting in changing at least one detectable characteristic of the arc.
Abstract:
A welding or additive manufacturing power supply includes output circuitry configured to generate a welding waveform, a current sensor for measuring a welding current generated by the output circuitry, a voltage sensor for measuring an output voltage of the welding waveform, and a controller operatively connected to the output circuitry to control the welding waveform, and operatively connected to the current sensor and the voltage sensor to monitor the welding current and the output voltage. A portion of welding waveform includes a controlled change in current from a first level to a second level different from the first level. The controller is configured to determine a circuit inductance from the output voltage and the controlled change in current, and further determine a change in resistance of a consumable electrode in real time based on the circuit inductance.
Abstract:
The invention described herein generally pertains to a system and method related to reducing magnetic arc blow during a welding operation performed by a welding system. In accordance with one embodiment of the invention, a welding system including a waveform generator generates a waveform that is switched from a positive current to a negative current, while passing through zero, in a step-wise fashion to resist the magnetic field within the material (e.g., the workpiece). In accordance of another embodiment of the invention, the welding system includes a nickel flux cord welding wire.
Abstract:
A method of preventing arc flaring events for a welding system is provided. The method includes determining, by a controller, a real-time welding output characteristic of the welding system. The method additionally includes comparing, by the controller, the real-time welding output characteristic to a threshold welding output characteristic. The method further includes controlling an operating characteristic of the welding system in response to a determination that the real-time welding output characteristic exceeds the threshold welding output characteristic.
Abstract:
A system for controlling arc length by regulating short circuit events during a welding process includes a welding power supply configured to conduct a free flight transfer pulsed arc welding process between a welding electrode and a workpiece, and a controller operatively connected to the welding power supply to control a welding waveform of the free flight transfer pulsed arc welding process. The controller is configured to automatically determine whether or not tethered incipient short circuits are included in said welding waveform, monitor a short circuit event characteristic during the free flight transfer pulsed arc welding process, and automatically adjust, based on said short circuit event characteristic, at least one parameter of said welding waveform to regulate tethered incipient short circuiting of the welding electrode to the workpiece during the free flight transfer pulsed arc welding process after determining that tethered incipient short circuits are included in said welding waveform.
Abstract:
A welding system includes a consumable welding electrode, a feeder that advances the consumable welding electrode toward a weld puddle during a welding operation, and a power supply configured to provide a series of welding waveforms to the consumable welding electrode to generate a welding current in the consumable welding electrode. An individual welding waveform of said series includes a predetermined minimum current portion, a peak current portion, and a background current portion having a magnitude that is greater than the minimum current portion and less than the peak current portion. The power supply comprises an adjustable resistance for setting a magnitude of the minimum current portion. The adjustable resistance is connected in series with the consumable welding electrode such that the minimum current portion of the welding current flows through the adjustable resistance.
Abstract:
An alternating current (AC) welding waveform, with two or more polarity changes during each molten metal droplet transfer cycle, is produced. The consumable welding electrode speed is mechanically controlled and the polarity is linked to known information about the electrode speed/direction, ensuring that at least two polarity changes are achieved per droplet transfer cycle. The arc polarity is concurrent with the change in direction of the electrode motion. The polarity can be changed based upon an actual speed of the electrode. Controlling the electrode motion and polarity in this way allows larger droplets to be created and higher deposition rates to be achieved at a lower frequency of shorting. The lower frequency of shorting also reduces wire feeder motor heating and wear, and increases contact tip life.
Abstract:
A method of preventing arc flaring events for a welding system is provided. The method includes determining, by a controller, a real-time welding output characteristic of the welding system. The method additionally includes comparing, by the controller, the real-time welding output characteristic to a threshold welding output characteristic. The method further includes controlling an operating characteristic of the welding system in response to a determination that the real-time welding output characteristic exceeds the threshold welding output characteristic.
Abstract:
A system and method generates a short circuit arc welding waveform output, having a pinch phase with a break point and a necking threshold, between a welding electrode and a work piece during a short circuit arc welding process. A necking threshold energy and a break point energy of the short circuit arc welding waveform output are monitored during the short circuit arc welding process, and a running average of the necking threshold energy is generated. An actual pinch energy relationship value is calculated based on the running average of the necking threshold energy and the break point energy, and is compared to a previously specified pinch energy relationship value. The break point energy of the short circuit arc welding waveform output is adjusted in response to the comparison to maintain the actual pinch energy relationship value to be at the specified pinch energy relationship value.