Illinois Tool Works Inc.

Caleb Haven

Richard Martin Hutchison

Peter Donald Mehn

James Lee Uecker

Bryan Dustin Marschke

Michael Todd Klegin

A welding system and method provide for generating a controlled waveform for welding power output, the waveform comprising a plurality of successive peak phases designed to avoid or reduce micro-arcing when used with metal-cored or flux-cored electrode wires. Ratios of the background current and voltage levels are elevated as compared to conventional techniques, with the levels in most cases exceeding 50% of the peak currents and voltages. Transitions between background and peak levels of current and voltage are also smoothed, and the duration of the peak phase as compared to the duration of each pulse cycle is elongated to further reduce micro-arcing.

Welding system and method for shielded welding wires

A welding regime may implements cyclic short circuits under a closed loop voltage control approach. Upon clearing or imminent clearing of the short circuit, a current recess is implemented. The current recess reduces the current that would otherwise be applied to the weld, resulting in multiple benefits. The recess may be implemented by suspending voltage command signals. Following the current recess, normal control is resumed with the then-current voltage command.

Reduced energy welding system and method

A method of operating a welding system includes supplying a weld current and a weld voltage to an electrode via a plurality of pulse periods, where each pulse period of the plurality of pulse periods includes a background phase and a peak phase. The method also includes detecting the occurrence of an anomalous cathode event during the background phase of a first pulse period of the plurality of pulse periods based at least in part on when a voltage value of the weld voltage is greater than a detect voltage. The method also includes controlling the weld current to a desired current during a portion of the anomalous cathode event. The portion includes an interval of the background phase of the first pulse period, and the weld current is controlled independent of the weld voltage during the portion of the anomalous cathode event.

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Appleton, WI, United States of America

Caleb Haven