Patent ID: 7645960

Claim:
A method of monitoring, controlling or combinations thereof at least one welding parameter of an electric arc welding process including the steps of: a) providing an encoded metal welding wire, said welding wire including an outer surface having a plurality of modified cross-sections, a first and second cross-section of the plurality of cross-sections having different cross-sectional sizes, different cross-sectional shapes, or combination thereof; b) detecting a change in electrical properties caused by said plurality of different cross-sectional sizes, different cross-sectional shapes, or combination thereof as said welding wire is fed through a welder to form a weld bead; c) measuring an amount of time passing between a first and second change in electrical properties caused by said plurality of different cross-sectional sizes, different cross-sectional shapes, or combination thereof; and d) using said detected change in electrical properties to monitor at least one welding parameter of an electric arc welding process, to control at least one welding parameter of an electric arc welding process, or combination thereof during said formation of said weld bead.