Welding power supply for pulsed spray welding

An arc welding machine for providing a continuous feed electrode to a weld site, comprising:

• line frequency transformer means including first and second secondary windings for receiving a line frequency power and for providing first and second welding powers, the second welding power having a higher voltage than the first welding power;
• first means for receiving the first welding power, for providing a welding power for a non-pulsed welding operation at a welding power output in a first mode, and for providing a background welding power for a pulsed welding operation at the welding power output in a second mode;
• and
• second means for receiving the second welding power and for providing a pulsed welding power at the welding power output.

An arc welding machine for providing a continuous feed electrode to a weld site, comprising:

• a power circuit to provide a pulsed welding power to the weld site;
• and
• a control circuit to provide control signals to the power circuit to control characteristics of the pulsed welding power;
• and
• operator controls configured to provide operator input signals to at least one of the power circuit and the control circuit, wherein the control circuit causes the power circuit to output a pulsed welding power having a fixed frequency and fixed pulse width irrespective of the operator input signals received from the operator controls, whereby the fixed frequency and fixed pulse width are substantially free of operator adjustment.

An arc welding machine for providing a continuous feed filler wire to a weld site, comprising:

• a single-phase AC power source to provide a power signal;
• a rectifier circuit coupled to the AC power source to substantially rectify the power signal and to provide the rectified power signal with a constant voltage characteristic to the weld site;
• and
• a switch coupled to the AC power source to provide a pulsed power signal with a constant current characteristic to the weld site, wherein the switch provides the constant current characteristic in an open loop configuration, without the use of a feedback circuit.

A power circuit for providing pulsed welding capability to a welding power supply, the welding power supply of the type having a line frequency transformer to provide a first welding power at a welding power output terminal, the power circuit comprising:

• a transformer to provide a second welding power;
• a switch coupled to the transformer to receive the second welding power;
• and
• a control circuit coupled to the switch to control the switch to provide a pulsed welding power at the welding power output terminal, the pulsed welding power having a fixed frequency and fixed pulse width which are fixed irrespective of operator input.