System for Arc Welding with Enhanced Metal Deposition

Abstract

A welding system includes a power supply configured to output power to a welding device. The power supply is configured to alternate the power output between an arc phase and a hotwire phase. The power output in the arc phase produces an arc between a welding electrode and a workpiece, and the power output in the hotwire phase heats the welding electrode without producing an arc.

1 . A welding system, comprising:
 a power supply configured to output power to a welding device, wherein the power supply is configured to alternate the power output between an arc phase and a hotwire phase;   wherein the power output in the arc phase produces an arc between a welding electrode and a workpiece; and   wherein the power output in the hotwire phase heats the welding electrode without producing an arc.   
     
     
         2 . The welding system of  claim 1 , wherein the power supply is configured to output the power at a cycle frequency. 
     
     
         3 . The welding system of  claim 2 , wherein the cycle frequency is within a range of approximately 1.0 to 10 Hertz. 
     
     
         4 . The welding system of  claim 2 , wherein the power supply is configured to operate at a constant duty cycle of the arc phase relative to the cycle frequency. 
     
     
         5 . The welding system of  claim 1 , comprising a welding wire feeder configured to advance the electrode toward the workpiece at a first feed rate during the arc phase and at a second feed rate during the hotwire phase. 
     
     
         6 . The welding system of  claim 1 , wherein the power supply is configured to provide signals to a welding wire feeder to adjust a wire feed speed to maintain the power output in the hotwire phase. 
     
     
         7 . The welding system of  claim 1 , wherein the welding device is configured to move the welding electrode away from the workpiece during a transition from the hotwire phase to the arc phase. 
     
     
         8 . The welding system of  claim 1 , wherein the power supply is configured to output the power to the electrode in both the arc and hotwire phases. 
     
     
         9 . The welding system of  claim 1 , wherein the power supply is configured to adjust a current to maintain the power output in the hotwire phase. 
     
     
         10 . The welding system of  claim 1 , wherein the power supply is configured to provide a higher power output during the arc phase than during the hotwire phase. 
     
     
         11 . The welding system of  claim 1 , wherein the power supply is configured to provide output power to the welding electrode via a first contact point of the welding device during the arc phase and to output power to the welding electrode via a second contact point of the welding device during the hotwire phase. 
     
     
         12 . A welding power supply, comprising:
 control circuitry configured to cycle welding power output from the power supply to a welding electrode between an arc phase and a hotwire phase;   wherein the control circuitry conditions the welding power to produce an arc between the welding electrode and a workpiece in the arc phase; and   wherein the control circuitry conditions the welding power to heat the welding electrode without producing an arc in the hotwire phase.   
     
     
         13 . The welding power supply of  claim 12 , wherein the power supply is configured to supply the welding power output for a predetermined amount of time in the arc phase and for another predetermined amount of time in the hotwire phase for each cycle. 
     
     
         14 . The welding power supply of  claim 12 , wherein the control circuitry is configured to provide control signals for adjusting a current of the power output or a position of an electrode contact point to maintain the power output in the hotwire phase. 
     
     
         15 . The welding power supply of  claim 12 , wherein the control circuitry conditions the power output to alternate between relatively high power in the arc phase and relatively low power in the hotwire phase. 
     
     
         16 . A welding system, comprising:
 a welding torch configured to direct a welding electrode toward a workpiece; and   a power supply configured to provide power to the welding torch in an arc phase and in a hotwire phase, alternating between the arc phase and the hotwire phase;   wherein a current heats the welding electrode without producing an arc between the welding electrode and the workpiece in the hotwire phase.   
     
     
         17 . The welding system of  claim 16 , wherein a separate current flows through an inductive heating element of the welding torch to provide additional heat to the welding electrode in the arc phase, the hotwire phase, or both. 
     
     
         18 . The welding system of  claim 16 , wherein the power supply is configured to provide the power to the welding electrode via a first contact point of the welding torch during the arc phase and to provide the power to the welding electrode via a second contact point of the welding torch during the hotwire phase. 
     
     
         19 . The welding system of  claim 16 , wherein the power supply is configured to adjust a welding parameter based on sensor feedback to maintain the power in the hotwire phase for a predetermined amount of time. 
     
     
         20 . The welding system of  claim 16 , wherein the power supply is configured to alternate between providing power in the arc phase and in the hotwire phase at a predetermined frequency.