Head assembly for multi-wire submerged arc welding (SAW)

An electrode head for a welding machine having one or more welding power sources and one or more electrode drives, comprising:

• an electrode head body having a plurality of apertures adapted to convey a plurality of associated continuous feed electrodes that are consumable to which current is applied to melt the continuous-feed electrodes for depositing material onto an associated workpiece;
• a contact assembly adapted to receive the plurality of associated continuous feed electrodes from the electrode head for establishing respective welding arcs, wherein the contact assembly is adapted to fixedly attach to the electrode head body;
• a drive roll that continuously delivers the associated multiple, continuous-feed electrodes for movement through the electrode head and through the contact assembly in which the associated multiple, continuous-feed electrodes are melted to deposit material on the surface of the associated workpiece;
• and
• the contact assembly comprises:
• a first contact bar and a second contact bar;
• the second contact bar includes a first flat side that includes a first set of grooves in which a groove of the set corresponds to one of a thickness of one of the associated multiple, continuous-feed electrodes and the groove allows for guided movement of one of the associated multiple, continuous-feed electrodes to deposit material on the surface of the workpiece;
• the first contact bar includes a first flat side;
• and
• an assembly connective means affixing the first contact bar to the second bar, wherein the first flat side of the second contact bar contacts the first flat side of the first contact bar encasing each of the associated multiple, continuous-feed electrodes between the first contact bar and the second contact bar within a respective grooved channel of the first set of grooves.

A welding device for depositing material on a surface of an associated workpiece, comprising:

• an electrode head adapted to concurrently house an array of associated multiple, continuous-feed electrodes that are consumable in a spaced apart configuration to which current is applied to melt the continuous-feed electrodes for concurrently depositing material on the surface of the associated workpiece;
• the electrode head includes a plurality of apertures adapted to receive the associated multiple, continuous-feed electrodes;
• and
• a contact assembly coupled to the electrode head and adapted to receive the associated multiple, continuous-feed electrodes from the electrode head,
• a drive roll that continuously delivers the associated multiple, continuous-feed electrodes for movement through the electrode head and through the contact assembly in which the associated multiple, continuous-feed electrodes are melted to deposit material on the surface of the associated workpiece;
• the contact assembly comprises:
• a first contact bar and a second contact bar;
• the first contact bar includes a first flat side and the second contact bar includes a first flat side;
• the first contact bar and the second contact bar are constructed from a first material;
• at least one of the first contact bar incorporates an insert on the first flat side or the second contact bar incorporates an insert on the first flat side, the insert is constructed from a second material that is more conductive than the first material;
• and
• an assembly connective means affixing the first contact bar to the second bar, wherein a first flat side of the second contact bar contacts the first flat side of the first contact bar encasing each of the associated multiple, continuous-feed electrodes between the first contact bar and the second contact bar within a respective groove of the set of grooves.