Method and system of using a consumable and a heat source with a weld puddle

A system for controlling filler wire, the system comprising:

• a high intensity energy source configured to heat at least one workpiece to create a molten puddle on a surface of said at least one workpiece;
• a filler wire feeder configured to feed a filler wire into said molten puddle;
• at least one controller configured to control advancing each of said high intensity energy source and said filler wire in a travel direction to deposit said filler wire on said at least one workpiece,
• wherein said at least one controller is further configured to obtain a desired shape, profile, height, size, or admixture of a bead formed by said molten puddle by:
• controlling movement said filler wire in at least a first direction, different from said travel direction, during feeding of said filler wire and advancing of said filler wire and said high intensity enemy source, and
• setting at least one of an angle of entry of said filler wire into said molten puddle with respect to a surface of said molten puddle and an offset of said filler wire with respect to a longitudinal axis of said molten puddle, wherein said movement of said filler wire in said at least first direction includes at least one of a back and forth motion that is in-line with said travel direction a back and forth motion that is transverse to said travel direction, a circular motion, an elliptical motion and a zig-zag motion, wherein the system further comprises:
• a second filler wire, wherein said at least one controller is configured to move said second filler wire in at least a second direction, different from said travel direction, during feeding of said second filler wire into said molten puddle,
• wherein said at least one controller is further configured to set at least one of an angle of entry of said second filler wire into said molten puddle with respect to said surface of said molten puddle and an offset of said second filler wire with respect to said longitudinal axis of said molten puddle, and
• wherein movement of said second filler wire in said at least second direction includes at least one of a back and forth motion that is in-line with said travel direction, a back and forth motion that is transverse to said travel direction, a circular motion, an elliptical motion, and a zig-zag motion.