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

The invention described herein generally pertains to a welding device that deposits a material onto a workpiece, the welding device having with an electrode head and a contact assembly coupled thereto. The contact assembly can include a rectangular-shaped first contact bar and a rectangular-shaped second contact bar that can be affixed to one another with an assembly connective means in order to encase a plurality of electrodes therebetween. The second contact bar can include a set of grooves in which each groove can correspond to an electrode to provide guidance during a welding procedure.

TECHNICAL FIELD

The invention described herein pertains generally to welding, and more particularly, to a head assembly for multi-wire Submerged Arc Welding (SAW).

BACKGROUND OF THE INVENTION

Metal parts frequently fail their intended use, due not only to fracturing but also to wear and abrasion, including mechanical wear (abrasion and pressure), chemical corrosion, and/or heat. Wear changes a metal part dimensionally and as such functionally. Processes are known for repairing worn metal parts where a durable material is adhered to the degraded surface. Similarly, a durable material may be adhered to a not previously worn surface which may be expected to experience wear. For metal components, this is commonly known as cladding or hard-facing, which can be defined as the application of building up wear-resistant material onto a parts surface by means of welding or joining. The cost of cladding is considerably less expensive than replacement costs and since cladding can be applied to a variety of base metals like: steel, stainless steel, nickel-based alloys, and copper-based alloys, it is widely used throughout the industry today.

A multi-wire SAW is a welding device that can perform cladding. The multi-wire SAW can include an electrode head that is adapted to receive a plurality of electrode contact tips. Each of the contacts tips may be associated with one of the electrodes. The contact tips can be releasably secured to the electrode head. For instance, conventional multi-wire SAW welding devices include an electrode head with apertures adapted to securely receive each of the contact tips respectively. Most conventional techniques include threads within the apertures as well as include corresponding threads on the contact tips for insertion into and removal from the electrode head as needed. Other techniques include set screws that, when tightened, prevent the contact tips from unintentionally dislodging.

Contact tips can wear in a short duration of time during cladding welding operations. When the contact tips wear out or deteriorate, new contact tips can be used for replacement tips. Replacing or repairing individual contact tips can be a cumbersome and timely maintenance procedure based on a location within or on the electrode head as well as the type of attachment to the electrode head (e.g., individual threads on contact tips, among others). Often, a contact tip holder can be used to hold a plurality of contact tips in place (rather than each tip using a releasably secure mechanism). However, each time a contact tip is replaced, the nozzle of the welding device is lifted to gain access to the contact tips. Such procedure often increases downtime and decreases operational productivity for a welding device that performs cladding operations.

Techniques and mechanisms for changing contact tips in an electrode head for a welding device can be time-consuming due to the location of the contact tips or the type of attachment to the electrode head. Moreover, replacement of contact tips can often require movement of the nozzle of the welding device which can be time-consuming and decrease the accuracy of the cladding operation. What is needed is a time efficient and non-evasive technique or mechanism that facilitates replacement of contact tips used by a welding device.

SUMMARY OF THE INVENTION

In accordance with the present invention, there is provided for deposition of material onto an associated workpiece resulting from the flow of electrical current through a plurality of associated continuous feed electrodes, comprising the steps of: providing a welding device that includes an electrode head adapted to concurrently house an array of associated multiple, continuous-feed electrodes in a spaced apart configuration 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, a contact assembly coupled to the electrode head and adapted to receive the associated multiple, continuous-feed electrodes. The contact assembly includes a first contact bar that is rectangular-shaped and a second contact bar that is rectangular-shaped, 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 the associated multiple, continuous-feed electrodes, 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 groove of the set of grooves.

In accordance with the present invention, there is provided 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 in a spaced apart configuration 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, a contact assembly coupled to the electrode head and adapted to receive the associated multiple, continuous-feed electrodes. The contact assembly can include a first contact bar that is rectangular-shaped and a second contact bar that is rectangular-shaped, 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 the associated multiple, continuous-feed electrodes, 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 groove of the set of grooves.

In accordance with the present invention, there is provided 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 for depositing material onto an associated workpiece, a contact assembly adapted to receive the plurality of associated continuous feed electrodes for establishing respective welding arcs, wherein the contact assembly is adapted to fixedly attach to the electrode head body. The contact assembly includes a first contact bar that is rectangular-shaped and a second contact bar that is rectangular-shaped, 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 the associated multiple, continuous-feed electrodes, 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 set of grooves.

These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims.

DETAILED DESCRIPTION OF THE INVENTION

The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time of the filing of this patent application. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims. Referring now to the drawings, wherein the showings are for the purpose of illustrating an exemplary embodiment of the invention only and not for the purpose of limiting same,FIGS. 1-14illustrate contact assembly10for welding device100. It is envisioned that device100may typically be used to clad or hard-face a workpiece by a submerged arc or electroslag welding process, although other welding processes such as GMAW, FCAW, TIG, and laser welding may also be employed. Cladding or hard-facing may be defined as a process by which cladding material is adhered to the surface of an existing component, known as a substrate or workpiece. The process bonds or infuses the cladding material or filler wire, which may be harder than the component material. In this manner, the cladding material comprises a wear resistant surface and a barrier to abrasion, erosion and heat during use.

As illustrated inFIG. 1, welding device100includes contact assembly10coupled to electrode head20, wherein electrode head20concurrently houses array30of multiple, continuous-feed electrodes32. Electrodes32may be gas-shielded, self-shielded, or metal cored. These electrodes may be solid core, metal core, or flux cored wires, to be used under gas shielding, under a submerged arc flux, or in an electroslag process. In the instance of cored electrodes, it is contemplated that the electrode sheath may be carbon steel, stainless steel, or a nickel alloy. Electrode head20houses array30such that electrodes32are in a spaced apart configuration for concurrently depositing material on a surface of an associated workpiece. Electrode head20may further include plurality of apertures130(better illustrated inFIG. 3) to receive multiple, continuous-feed electrodes32. Electrodes32may be provided from coil40. Coil40may include a plurality of individual coils, each coil containing a single electrode, which are arranged along a common axis of rotation. Still any manner of delivering filler wire or cladding material may be chosen without departing from the intended scope of coverage of the embodiments of the subject invention. In an embodiment, electrode head20can include an additional set of a plurality of apertures190(better illustrated inFIG. 3) on a disparate side (in comparison to the plurality of apertures130) of electrode head20. For instance, plurality of apertures130can correspond to a gauge(s) (e.g., thickness) of electrode(s), whereas plurality of apertures190can correspond to a different gauge(s) (e.g., thickness) of electrode(s). For example, plurality of apertures130can correspond to 0.045 inch wire (e.g., electrodes) and plurality of apertures190can correspond to 1/16inch wire (e.g., electrodes). Still, other gauges for each set of apertures130,190be employed with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

As illustrated inFIG. 1, contact assembly10is coupled to electrode head20and adapted to receive array30of associated multiple, continuous-feed electrodes32. Contact assembly10replaces conventional techniques and mechanisms associated with contact tips. Rather than an individual contact tip for each of the continuous-feed electrodes32, contact assembly10provides a universal housing that collectively encases each electrode32. Moreover, contact assembly10, as discussed in more detail below, allows access to electrodes and such housing without movement of a nozzle on welding device100.

Welding device100includes means for concurrently driving array30of electrodes32through electrode head20. It is envisioned that the means for driving includes plurality of drive rolls50or other wire feeder device. Each of the plurality of drive rolls50may be associated with one or more of electrodes32. In one aspect, two electrodes32may be associated with a single set of drive rolls50, although it is envisioned that the relationship between the number of electrodes and the number of wire feeders may be configured such that any number of electrodes may be associated with a single set of drive rolls as appropriate in a cladding process without departing from the intent of the subject disclosure. In one example, drive rolls50may be configured to drive electrodes32through the electrode head20at substantially the same rate. Alternatively, drive rolls50are configured to feed electrodes32at slower and/or faster wire speeds/wire feed rates, where it may be desired to change the current needed to melt off the electrode, thereby changing the heat input by electrode32into the molten cladding material. For example, one set of drive rolls50may be configured to feed electrodes32arranged at the outside of array30at a one wire feed speed, while a different set of drive rolls50may be configured to feed electrodes32arranged at the inside of array30at a relatively lower wire feed speed as compared to the wire feed speed of the outer electrodes, so as to substantially reduce and/or eliminate the effects of the magnetic force induced by the flow of current through each electrode32.

In one aspect of the embodiments of the subject invention, each of the electrodes32are configured to be connected to welding power source60. That is to say that during the cladding process, for instance, welding power can be delivered through each of electrodes32in array30at substantially the same rate. Accordingly, cladding material is delivered substantially uniformly over a width of electrode head20. Uniform penetration of the substrate is also achieved. As indicated above, power may be delivered from the welding power source60through welding cables (not shown) as attached at one end to studs (not shown). At the distal end, welding cables may be connected to electrode head20through an electrode head connector. In the exemplary case of a single welding power source60, a single electrode head connector may convey power from the welding cables commonly to contact assembly10affixed to electrode head20. Still, other means for conveying power from the welding cables to electrode head20may be employed with sound engineering judgment.

FIGS. 1-14illustrate contact assembly10for performing a welding operation. In one aspect, contact assembly10includes first contact bar110and second contact bar120. Contact bars110,120are often rectangular-shaped. Furthermore, contact bars110,120include a length, a width, and a depth (e.g., a thickness). In an embodiment, first contact bar110is substantially similar in size and/or shape to second contact bar120. In another embodiment, first contact bar110includes a first length and second contact bar120include a second length, where the first length is less than the second length. Additionally, first contact bar110can include a substantially similar width and/or depth (e.g., thickness). In another embodiment, first contact bar110is constructed from a material selected from the group consisting of a copper, an alloy of copper, beryllium copper, copper tungsten, a conductive metal, among others. In yet another embodiment, second contact bar120can be constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others. Yet, any shape, size, dimensions, or material may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

As illustrated inFIGS. 2-8, one embodiment includes contact bars110,120each being rectangular-shaped. First contact bar110includes first flat side112parallel to a second flat side (opposite thereof) and includes a thickness with at least four (4) sides interconnecting first flat side112and the second flat side opposite thereof. Second contact bar120includes first flat side114parallel to a second flat side (opposite thereof) and includes a thickness with at least four (4) sides interconnecting first flat side114and the second flat side opposite thereof.

Moreover, first contact bar110includes first flat side112(illustrated inFIG. 4), and second contact bar120can include flat side114(illustrated inFIG. 6). First flat side112and first flat side114are in contact based on assembly connective means170. In an embodiment, first flat side112and first flat side114are within a distance of one another such that the electrodes32are wedged therebetween, wherein the distance is in the range of zero (0) (e.g., tight and in contact) to approximately half a diameter of the electrode32. For instance, an electrode gauge of 0.045 can have a distance from zero (0) to 0.023 inches. Yet, as first contact bar110and second contact bar120wear, the distance is reduced to zero which enables contact between first contact bar110and second contact bar120. In another embodiment, first contact bar110includes a second flat side opposite and parallel of first flat side112on first contact bar110. In still another embodiment, second contact bar120includes a second flat side opposite and parallel of first flat side114on second contact bar120.

In an embodiment, second contact bar120includes first flat side114that includes at least one groove150(where one or more grooves are referred to as set of grooves140). For instance, a groove can correspond to each of associated multiple, continuous-feed electrodes32. In another instance, a width of groove150corresponds to a thickness of a corresponding continuous-feed electrode32in which groove150of the set corresponds to one of associated multiple, continuous-feed electrodes32. For example, each groove150includes a width that is approximate to a diameter for at least one of associated multiple, continuous-feed electrodes32.

In still another embodiment, second contact bar120includes second set of grooves160(e.g., an extra set of grooves) on a side opposite of first flat side114on second contact bar120(e.g., the side opposite of first flat side114on second contact bar120can be referred to as a second flat side). Second set of grooves160can correspond to a second width or thickness related to a diameter of electrodes32. For example, each groove of the set of grooves160can include a width that is approximate to a diameter for at least one of associated multiple, continuous-feed electrodes32. Any width or electrode diameter (e.g., gauge) may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

Contact assembly10can further include assembly connective means170affixing first contact bar110to second contact bar120. Assembly connective means170connects first contact bar110to second contact bar120, wherein first flat side114of second contact bar120is in contact with first flat side112of first contact bar110. Contact and connection between first contact bar110and second contact bar120can encase each of associated multiple, continuous-feed electrodes32between first contact bar110and second contact bar120within a respective groove150of set of grooves140.

In an embodiment, assembly connective means170includes a pressure-spring clamp mechanism that secures associated multiple, continuous-feed electrodes32in between first contact bar110and second contact bar120. For example, assembly connective means170can include at least one bolt, nut, washer, and spring. By way of example and not limitation, contact assembly10is illustrated with assembly connective means170as a bolt, a spring, and/or a nut. As illustrated inFIG. 4, first aperture177is included on one end of each first contact bar110and second contact bar120such that first aperture177aligns with both first contact bar110and second contact bar120. Moreover, second aperture178is included on an opposite end of the one end such that second aperture178aligns with both first contact bar110and second contact bar120. At least one bolt assembly can be used to affix first contact bar110to second contact bar120, wherein the at least one bolt assembly can include a bolt, a spring, and a nut. In an embodiment, the bolt assembly for first aperture177can include bolt171, spring173, and nut175(as shown inFIG. 2). In an embodiment, the bolt assembly for second aperture178can include bolt172, spring174, and nut176(as shown inFIG. 2). Still, other means for affixing first contact bar110to contact bar120may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

Contact assembly10can include welder device connective means180. As shown inFIGS. 2-8andFIGS. 10-12, welder device connective means180can couple contact assembly10to welding device100. In an embodiment, welder device connective means180can be a bolt assembly that includes a bolt, a washer (optional), a nut, and an aperture for which the bolt assembly can be inserted. For instance, a bolt assembly can be used on each end of second contact bar120(e.g., one bolt assembly for each end) to connect contact assembly10to welding device100. Still, other means for affixing contact assembly10may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

In an embodiment, assembly connective means170can be utilized to affix first contact bar110to second contact bar120as well as to couple contact assembly10to welding device100. In a particular embodiment, assembly connective means170(e.g., bolt assembly, among others) can couple contact assembly10to welding device100and, in addition, affix first contact bar110to second contact bar120.

In an embodiment, first contact bar110can include insert200(as shown inFIGS. 12-13). Insert200can provide an additional resistance to wear from electrodes sliding therebetween or thereby based on being constructed from first material while first contact bar110is construction from a second material. In another example, insert200can be constructed from a conductive material so as to reduce cost by using a less amount of expensive conductive materials (e.g., conductive material for insert200rather than entire first contact bar110). Insert200can be incorporated into first contact bar110such that insert200can include a depth (e.g., thickness), a length, and a width. In an embodiment, insert200includes a length that is less than or equal to a length of first contact bar110, a width that is less than or equal to a width for first contact bar110, and a depth (e.g., thickness) that is less than a depth for first contact bar110. By way of example and not limitation, insert200includes a surface area for a surface (e.g., surface that is in contact with first flat side114of second contact bar120) that is greater than or equal to a surface area on a surface that includes set of grooves140. For instance, if the set of grooves span for a length of 5 inches and has a width of 5 inches on a second contact bar and second contact bar has with a length of 10 inches and a 5 inch width, the surface area for insert200can be equal to or greater than 25 square inches (e.g., surface area needed for a space of the set of grooves is 5 inches×5 inches=25 square inches). It is to be appreciated that insert200can provide a material different from first contact bar110to prevent wear and/or deterioration for electrodes32encased within set of grooves140. Further, it is to be appreciated and understood that insert200can be constructed from a first material and first contact bar110can be constructed from a second material.

In another embodiment, second contact bar120can include insert210(shown inFIGS. 12-13). Insert210can provide an additional resistance to wear from depositing material on the workpiece based on construction from first material while second contact bar120is construction from a second material. In another example, insert210can be constructed from a conductive material so as to reduce cost by using a less amount of expensive conductive materials (e.g., conductive material for insert210rather than entire second contact bar120). Insert210can be incorporated into second contact bar120such that insert210includes a depth (e.g., thickness), a length, and a width. In another embodiment, insert210includes a length that is less than or equal to a length of second contact bar120, a width that is less than or equal to a width for second contact bar120, and a depth (e.g., thickness) that is less than a depth for second contact bar120. By way of example and not limitation, insert210includes a surface area for a surface (e.g., surface that is in contact with first flat side112of first contact bar110) that is greater than or equal to a surface area needed to span or include set of grooves140. For instance, if the set of grooves span for a length of 5 inches and has a width of 5 inches on a second contact bar and second contact bar has with a length of 10 inches and a 5 inch width, the surface area for insert210can be equal to or greater than 25 square inches (e.g., surface area needed for a space of the set of grooves is 5 inches×5 inches=25 square inches). Further, second contact bar120includes set of grooves140on first flat side114, yet insert210can include a first flat side and include set of grooves140thereon. It is to be appreciated that insert210can provide a material that is different from second contact bar120to prevent wear and/or deterioration for electrodes32encased within set of grooves140as well as an electrical conductor for electrodes32. Further, it is to be appreciated and understood that insert210can be constructed from a first material and second contact bar120can be constructed from a second material.

In another embodiment, first contact bar110includes first insert200(also referred to as insert200) and second contact bar120includes second insert210(also referred to as insert210). First insert200is incorporated into first contact bar110and second insert210is incorporated into second contact bar120. First insert200has a depth (e.g., thickness), a length, and a width and second insert210has a depth (e.g., thickness), a length, and a width. In an embodiment, first insert200includes a length that is less than or equal to a length of first contact bar110, a width that is less than or equal to a width for first contact bar110, and a depth (e.g., thickness) that is less than a depth for first contact bar110. In another embodiment, second insert210includes a length that is less than or equal to a length of second contact bar120, a width that is less than or equal to a width for second contact bar120, and a depth (e.g., thickness) that is less than a depth for second contact bar120.

By way of example and not limitation, first insert200and second insert210can include respective surface areas (e.g., first flat side112and first flat side114, surfaces in contact, and the like) that are approximate in dimensions to each other. In another example, the respective surface areas for first insert200and second insert210can be equal to or greater than a surface area associated with set of grooves140(or in the alternative set of grooves160). In an embodiment, the respective surface areas for first insert200and second insert210cover a surface area accounting for electrodes32encased between first contact bar110and second contact bar120. For instance, inserts200,210are sized to a surface area that includes set of grooves140.

In a particular embodiment, insert200is constructed from a material selected from the group consisting of a copper, an alloy of copper, beryllium copper, copper tungsten, a conductive metal, among others, whereas first contact bar110is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others. In such embodiment, second contact bar120is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others.

In a particular embodiment, insert210is constructed from a material selected from the group consisting of a copper, an alloy of copper, beryllium copper, copper tungsten, a conductive metal, among others, whereas second contact bar120is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others. In such embodiment, first contact bar110is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others.

In a particular embodiment, first insert200is constructed from a material selected from the group consisting of a copper, an alloy of copper, beryllium copper, copper tungsten, a conductive metal, among others, first contact bar110is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others, second insert210is constructed from a material selected from the group consisting of a copper, an alloy of copper, beryllium copper, copper tungsten, a conductive metal, among others, and second contact bar120is constructed from a material selected from the group consisting of a steel, a copper, a ceramic, among others.

By way of example and not limitation, insert200can be incorporated into or onto first contact bar110with at least one of a fastener, a press-fit, a friction fit, among others. Still, other means for incorporating insert200into or onto first contact bar110may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. By way of example and not limitation, insert210can be incorporated into or onto second contact bar120with at least one of a fastener, a press-fit, a friction fit, among others. Still, other means for incorporating insert210into or onto second contact bar120may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention.

First contact bar110can be affixed to second contact bar120with assembly connective means170as shown inFIGS. 2,3, and12. In particular, assembly connective means170provide a spring-like mechanism in order to apply an even pressure or force on electrodes32encased between first contact bar110and second contact bar120and respectively positioned in each groove150. Moreover, contact assembly10is coupled to welding device100with welder device connective means180. As shown inFIGS. 2,3, and12, assembly connective means170facilitates performing maintenance repairs on contact assembly10without removing electrodes32from respective grooves150from set of grooves140and/or lifting a nozzle of welding device100.

As discussed above, first contact bar110is essentially rectangular-shaped with first flat side112and a second flat side opposite of first flat side112, wherein first flat side112is parallel to second flat side. Second contact bar120is essentially rectangular-shaped with first flat side114and a second flat side opposite of first flat side112, wherein first flat side114is parallel to second flat side. Still, other shapes or sizes for first contact bar110and/or second contact bar120may be chosen with sound engineering judgment without departing from the intended scope of coverage of the embodiments of the subject invention. First flat side112and second flat side opposite thereof includes a thickness and at least four (4) sides interconnecting first flat side112and the second flat side opposite thereof. The rectangular-shaped first contact bar110allows a rotation thereof about an axis in order to provide one of the sides in contact (e.g., first flat side112, first flat side114, and the like) with second contact bar120and in particular, set of grooves140. For instance, contact bar110includes first flat side112(and an edge) in contact with first flat side114of second contact bar120and a rotation (e.g., a half rotation, among others) of first contact bar110about a longitudinal axis can provide the second flat side (and a respective edge) opposite of the first flat side112in contact with first flat side114of second contact bar120. Similarly, contact bar110can include first flat side112(and an edge) in contact with first flat side114of second contact bar120and a rotation (e.g., a half revolution, among others) of first contact bar110about a latitudinal axis can provide the second flat side (and a respective edge) opposite of the first flat side112in contact with first flat side114of second contact bar120. For instance, an edge on first contact bar110on first flat side112can be worn from use with depositing material in a welding operation with contact assembly10. The first contact bar110can be rotated about a longitudinal axis to provide a fresh (unworn) edge to contact second contact bar120and/or first contact bar110can be rotated about a latitudinal axis to provide a fresh (unworn) edge to contact second contact bar120. It is to be appreciated that a combination of rotation about both the latitudinal axis and the longitudinal axis can be used to access each edge or side of first contact bar110.

With reference to all of theFIGS. 1-14, method1500is a flow diagram of depositing cladding material onto an associated workpiece resulting from the flow of electrical current through a plurality of associated continuous feed electrodes is illustrated. Method1500may include the steps of providing a welding device including an electrode head adapted to house an array of multiple, continuous-feed electrodes for concurrently depositing material on the surface of the associated workpiece, wherein the electrode head can include a plurality of apertures adapted to receive electrodes (reference block1510). The provided welding device further includes a contact assembly coupled to the electrode head receives electrodes (reference block1520). The contact assembly is provided that further includes a first contact bar that is rectangular-shaped having a first flat side and a second contact bar that is rectangular-shaped (reference block1530). Contact assembly can be provided that further includes the second contact bar having a first flat side that includes a first set of grooves in which a groove of the set corresponds to one of the electrodes (reference block1540). Contact assembly is provided that includes an assembly connective means that affixes the first contact bar to the second contact 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 electrodes between the first contact bar and the second contact bar within a respective groove of the set of grooves (reference block1550).

In an embodiment, the method can further include establishing a welding arc between each of the associated multiple, continuous-feed electrodes and the associated workpiece for depositing material onto the surface of the associated workpiece. In another embodiment, the method can include at least one of rotating the first contact bar about a longitudinal axis for half a revolution, the rotation relieves an edge on the first contact bar that is worn from deposition of material onto an associated workpiece (e.g., rotation of the first contact bar presents an unworn edge or an edge that has not been used in the welding operation), or rotating the first contact bar about a latitudinal axis for half a revolution, the rotation relieves an edge on the first contact bar that is worn from deposition of material onto an associated workpiece (e.g., rotation of the first contact bar presents an unworn edge or an edge that has not been used in the welding operation). In an embodiment, the method can further include grinding a portion of the first contact bar to remove wear from deposition of material onto the associated workpiece.

The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof.