Dual wire welding or additive manufacturing system and method

A method of welding or additive manufacturing, comprising the steps of:

• providing a torch including a contact tip assembly having a first exit orifice for a first wire electrode and a second exit orifice for a second wire electrode, wherein the first and second exit orifices of the contact tip assembly are separated from each other such that a distance S is provided between the first wire electrode and the second wire electrode;
• adjusting the distance S provided between the first wire electrode and the second wire electrode;
• providing a current waveform to both of the first wire electrode and the second wire electrode through the contact tip assembly, wherein the current waveform includes a peak current level, a background current level, and a bridging current level;
• and
• forming a bridge droplet between the first wire electrode and the second wire electrode using the bridging current level of the current waveform, wherein the bridge droplet couples the first wire electrode and the second wire electrode prior to contacting a molten puddle during a deposition operation, wherein a current due to the current waveform flows from the contact tip assembly to the bridge droplet through both of the first wire electrode and the second wire electrode and the current is divided between the first wire electrode and the second wire electrode, and wherein the current flows from the bridge droplet to the molten puddle.

A method of welding or additive manufacturing, comprising the steps of:

• providing a torch including a contact tip assembly having a first exit orifice for a first wire electrode and a second exit orifice for a second wire electrode, wherein the first and second exit orifices of the contact tip assembly are separated from each other such that a distance S is provided between the first wire electrode and the second wire electrode;
• adjusting the distance S provided between the first wire electrode and the second wire electrode;
• providing a current waveform to both of the first wire electrode and the second wire electrode through the contact tip assembly;
• and
• forming a bridge droplet between the first wire electrode and the second wire electrode using the current waveform, wherein the bridge droplet couples the first wire electrode and the second wire electrode prior to contacting a molten puddle during a deposition operation, wherein the contact tip assembly includes:
• a first bore in communication with the first exit orifice;
• a second bore in communication with the second exit orifice;
• a third bore in communication with a third exit orifice;
• and
• a fourth bore in communication with a fourth exit orifice, and
• wherein the step of adjusting the distance S includes moving the first wire electrode from the first bore to the third bore or moving the second wire electrode from the second bore to the fourth bore.

A welding or additive manufacturing contact tip, comprising:

• an electrically-conductive body extending along an axis between a proximal end of the body and a distal end of the body, the body forming:
• a first bore through the body that extends from a first entrance orifice at the proximal end to a first exit orifice at the distal end;
• a second bore through the body extending from a second entrance orifice at the proximal end to a second exit orifice at the distal end;
• and
• a third bore through the body extending from a third entrance orifice at the proximal end to a third exit orifice at the distal end;
• and
• a mounting shank located at the proximal end of the body, wherein the mounting shank includes a tab having a tapered edge,
• wherein the first and second exit orifices are separated from each other by a first distance, and the second and third exit orifices are separated from each other by a second distance, wherein the first distance is different from the second distance, and both of the first distance and the second distance are configured to facilitate formation of a bridge droplet between at least two wire electrodes delivered through the contact tip, wherein the bridge droplet couples the at least two wire electrodes prior to contacting a puddle during a deposition operation.