Reduction of droplet size for CO2 shielded welding wire

An arc welding system providing improved molten metal droplet transfer, the arc welding system comprising:

• a welding power source including:
• a welding power supply,
• a welding waveform generator, and
• a controller;
• two flux cored welding wire electrodes operatively connected to the welding power source, where the two flux cored welding wire electrodes are powered by a same welding output voltage and welding output current produced by the welding power source;
• and
• a feedback circuit operatively connected to the welding power source to provide an adaptive response to maintain an average welding output voltage,
• wherein the controller is programmed to control at least the welding waveform generator and the welding power supply to superimpose welding current pulses onto a welding waveform of a constant voltage (CV) flux cored arc welding process, that uses CO2 as a shielding gas, to generate a modified waveform of a modified CV flux cored arc welding process, and
• where the superimposed welding current pulses are superimposed in time to facilitate formation of molten metal droplets between ends of the two fluxed cored welding wire electrodes during the modified CV flux cored arc welding process, resulting in the molten metal droplets being smaller in size, at times of transfer to a weld puddle, than otherwise would be without the superimposed welding current pulses.