US 12,427,596 B2
Hybrid projected and streaming pulse welding
Matthew A. Albright, Thompson, OH (US); Steven R. Peters, Huntsburg, OH (US); and Thomas Rastatter, Chagrin Falls, OH (US)
Assigned to LINCOLN GLOBAL, INC., Santa Fe Springs, CA (US)
Filed by Lincoln Global, Inc., Santa Fe Springs, CA (US)
Filed on Oct. 18, 2021, as Appl. No. 17/503,447.
Claims priority of provisional application 63/129,810, filed on Dec. 23, 2020.
Prior Publication US 2022/0193807 A1, Jun. 23, 2022
Int. Cl. B23K 9/09 (2006.01); B23K 9/04 (2006.01); B23K 9/10 (2006.01); B23K 9/29 (2006.01); B33Y 30/00 (2015.01)
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
OG exemplary drawing
 
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.