Method and system for heating consumable during hot wire

A hot-wire system, the system comprising:

• a laser beam system which directs a first laser beam at a surface of at least one workpiece to create a molten puddle on said surface and a second laser beam at a consumable prior to said consumable entering said molten puddle, said first laser beam and said second laser beam originating from a common source laser;
• a wire feeder which advances said consumable to said molten puddle so that said consumable contacts said molten puddle;
• a power supply which outputs a heating signal and said heating signal is directed to said consumable to heat said consumable prior to said consumable entering said puddle;
• and
• a controller which controls an output of each of said power supply and said laser beam system,
• wherein said controller monitors at least one of a voltage at, current through, resistance of, and temperature of said consumable and controls an output of at least one of said laser beam system and said power supply based on said monitoring so that said consumable melts in said molten puddle without generation of an arc between said consumable and said molten puddle.

A method of heating a consumable, the method comprising:

• directing a first laser beam at a surface of at least one workpiece to create a molten puddle on said surface;
• advancing a consumable to said molten puddle so that said consumable contacts said molten puddle;
• directing a heating signal to said consumable to heat said consumable prior to said consumable entering said puddle;
• directing a second laser beam at said consumable prior to said consumable entering said puddle;
• monitoring at least one of a voltage at, current through, resistance of, and temperature of said consumable;
• and
• controlling a power of at least one of said second laser beam and said heating signal based on said monitoring so that said consumable melts in said molten puddle without generation of an arc between said consumable and said molten puddle.

A method of heating a consumable, the method comprising:

• controlling a laser beam system to direct a first laser beam at a surface of at least one workpiece to create a molten puddle on said surface and a second laser beam at a consumable prior to said consumable entering said molten puddle, said first laser beam and said second laser beam originating from a common source laser;
• advancing said consumable to said molten puddle so that said consumable contacts said molten puddle;
• directing a heating signal to said consumable to heat said consumable prior to said consumable entering said puddle;
• monitoring at least one of a voltage at, current through, resistance of, and temperature of said consumable;
• and
• controlling a power of said second laser beam and said heating signal based on said monitoring so that said consumable melts in said molten puddle without generation of an arc between said consumable and said molten puddle.