| CPC B23K 9/092 (2013.01) [B23K 9/04 (2013.01); B23K 9/091 (2013.01); B23K 9/1062 (2013.01); B23K 9/295 (2013.01); B33Y 30/00 (2014.12); B23K 9/1006 (2013.01)] | 18 Claims |

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1. An arc welding or additive manufacturing system, comprising: a wire feeder; a torch; a wire electrode driven through the torch by the wire feeder; and an arc generation power supply operatively connected to the torch to deliver a pulse waveform to the wire electrode during a deposition operation, wherein the pulse waveform comprises a series of current pulses and interleaved background current portions such that each current pulse is separated from a prior current pulse by a prior background current portion and separated from a subsequent current pulse by a subsequent background current portion, and during each current pulse a molten droplet is projected from a tip of the wire electrode in a first metal transfer mode followed by an axial spray of molten metal away from the tip of the wire electrode in a second metal transfer mode different from the first metal transfer mode, before the subsequent background current portion occurs, wherein each current pulse comprises a peak current level that projects the molten droplet from the tip of the wire electrode, and a spray current level during which the axial spray of molten metal occurs, wherein the spray current level is less than the peak current level.
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