Dual wire welding or additive manufacturing system and method

A method of welding or additive manufacturing, comprising:

• providing a current waveform to a single contact tip having a first exit orifice and second exit orifice,
• providing a first consumable to said single contact tip such that said first consumable exits said first exit orifice;
• providing a second consumable to said single contact tip such that said second consumable exits said second exit orifice, where said first and second exit orifices are positioned from each other such that a distance S exists between said first and second consumables;
• and
• forming a bridging droplet between said first and second consumables using said current waveform, while preventing solid portions of the first consumable delivered through the first exit orifice from contacting solid portions of the second consumable delivered through the second exit orifice during a deposition operation, where said bridging droplet couples said first and second consumables before said bridging droplet transfers to a puddle during said deposition operation, wherein a current due to said current waveform flows from said single contact tip to the bridging droplet through both of the first consumable and the second consumable and the current is divided between the first consumable and the second consumable, and wherein the current flows from the bridging droplet to the puddle.

A welding or additive manufacturing system, comprising:

• at least one power supply and a controller which controls operation of said power supply, where said power supply provides a current waveform to a single contact tip having a first exit orifice and second exit orifice, where said first exit orifice is configured to deliver a first consumable and said second exit orifice is configured to deliver a second consumable;
• wherein said first and second exit orifices are separated from each other such that a distance S is provided between said first and second consumables;
• wherein said single contact tip is configured to deliver said current waveform to each of said first and second consumables;
• and
• wherein said distance S is configured to facilitate formation of a bridge droplet between said first and second consumables by said current waveform while preventing solid portions of the first consumable delivered through the first exit orifice from contacting solid portions of the second consumable delivered through the second exit orifice during a deposition operation, where said bridge droplet couples said first and second consumables prior to contacting a puddle during said deposition operation, and
• wherein a current due to said current waveform flows from said single contact tip to the bridge droplet through both of the first consumable and the second consumable and the current is divided between the first consumable and the second consumable, and wherein the current flows from the bridge droplet to the puddle.