Dual wire welding system and method

Abstract

A system and method of welding is provided where at least two welding electrodes are provided to and passed through a single orifice on a single contact tip and a welding waveform is provided to the electrodes through the contact tip to weld simultaneously with both electrodes.

What is claimed is: 
     
         1 . An arc welding system, comprising:
 a welding gun including a contact tip having a channel and an exit orifice;   an arc welding power supply which provides an arc welding waveform to at least two arc welding consumable electrodes having a circular cross-section via said contact tip; and   a wire feeding mechanism which provides said at least two arc welding consumable electrodes from respective electrode sources to said channel in said contact tip, where said arc welding electrodes pass through said channel in a longitudinal orientation without intertwining or twisting with each other and exit said contact tip through said exit orifice.   
     
     
         2 . The welding system of  claim 1 , wherein said channel is angled. 
     
     
         3 . The welding system of  claim 1 , wherein said orifice has either an elliptical or oval shape. 
     
     
         4 . The welding system of  claim 1 , wherein said channel has a cross-sectional shape at at least one point along its length which is different from the cross-sectional shape of said orifice. 
     
     
         5 . The welding system of  claim 1 , wherein said channel has a circular cross-section at at least one point along its length. 
     
     
         6 . The welding system of  claim 1 , wherein said contact tip is rotatable so as to change the orientation of said at least two electrodes relative to a weld bead. 
     
     
         7 . The welding system of  claim 1 , wherein said at least two electrodes have a different diameter from each other. 
     
     
         8 . The welding system of  claim 1 , wherein said at least two electrodes have a different composition. 
     
     
         9 . The welding system of  claim 1 , wherein said welding waveform provides a welding current sufficient to weld with a single electrode having a cross-sectional area substantially the same as the total cross-sectional area of said at least two electrodes. 
     
     
       10. An arc welding system, comprising:
 a welding gun including a contact tip having a channel and an exit orifice;   an arc welding power supply which provides an arc welding waveform through said contact tip for consuming two arc welding consumable electrodes having a circular cross-section;   a wire feeding mechanism; and   a liner disposed between a welding torch and said wire feeding mechanism,   wherein said wire feeding mechanism provides said two arc welding consumable electrodes from respective electrode sources through said liner to said welding torch, wherein said two arc welding electrodes pass through said liner in a longitudinal orientation without intertwining or twisting with each other to deliver said two arc welding electrodes to said channel in said contact tip, and wherein said two arc welding electrodes pass through said channel without intertwining or twisting with each other and exit said contact tip.   
     
     
       11. The welding system of  claim 10 , wherein said channel is bent. 
     
     
       12. The welding system of  claim 10 , wherein said channel has a circular cross-section at at least one point along its length. 
     
     
       13. The welding system of  claim 10 , wherein said contact tip comprises an inlet orifice. 
     
     
       14. The welding system of  claim 13 , wherein the orifice has a circular shape. 
     
     
       15. The welding system of  claim 10 , wherein said two electrodes have a different diameter from each other. 
     
     
       16. The welding system of  claim 10 , wherein said two electrodes have a different composition. 
     
     
       17. The welding system of  claim 10 , wherein said welding waveform provides a welding current. 
     
     
       18. The welding system of  claim 10 , wherein the wire feeding mechanism comprises one wire feeder receiving said two electrodes from separate electrode sources. 
     
     
       19. The welding system of  claim 10 , wherein said two electrodes are positioned to exit the welding torch with a space between said two electrodes. 
     
     
       20. The welding system of  claim 10 , wherein said wire feeding mechanism comprises a single pair of feed rollers configured to drive said two arc welding electrodes through said liner. 
     
     
       21. The welding system of  claim 10 , wherein said liner has an inner diameter of 0.0625 inches. 
     
     
       22. An arc welding system, comprising:
 a welding gun including a contact tip having a channel and an exit orifice;   an arc welding power supply which provides an arc welding waveform through said contact tip for consuming two arc welding consumable electrodes having a circular cross-section;   a wire feeding mechanism; and   a liner disposed between a welding torch and said wire feeder,   wherein said wire feeder drives said two arc welding consumable electrodes from respective electrode sources through said liner to said welding torch, wherein said two arc welding electrodes pass through said liner in a longitudinal orientation without intertwining or twisting with each other to deliver said two arc welding electrodes to said channel in said contact tip, and wherein said two arc welding electrodes pass through said channel without intertwining or twisting with each other and exit said contact tip,   wherein said wire feeding mechanism comprises a single pair of feed rollers configured to drive said two arc welding electrodes through said liner, said feed rollers being designed for a single wire feeding operation; and   wherein said liner is sized to allow for said two arc welding electrodes to pass therethrough to said welding torch.   
     
     
       23. The welding system of  claim 22 , wherein said liner has an inner diameter of 0.0625 inches. 
     
     
       24. The welding system of  claim 22 , wherein said channel is bent. 
     
     
       25. The welding system of  claim 22 , wherein said channel has a circular cross-section at at least one point along its length. 
     
     
       26. The welding system of  claim 22 , wherein said contact tip comprises an inlet orifice. 
     
     
       27. The welding system of  claim 24 , wherein said orifice has a circular shape. 
     
     
       28. The welding system of  claim 10 , wherein said wire feeding mechanism is designed for a single wire feeding operation. 
     
     
       29. The welding system of  claim 10 , wherein each of said arc welding electrodes has a diameter of 0.030 inches. 
     
     
       30. The welding system of  claim 22 , wherein each of said arc welding electrodes has a diameter of 0.030.