Retaining head and contact tip press fit components and methods

Abstract

A system for servicing a welding torch by means of cleaning the consumables and changing the welding contact tip. The system can be integrated into an automated welding cell where the cleaning and changing services can be completed automatically. A different method used to interlock the welding contact tip to the retaining head, or gas diffuser, results in simplified technology for an automated process. The welding contact tip may be shaped to press- fit, or interference fit, into the retaining head to securely fasten the tip to the retaining head during welding. The welding contact tip and retaining head may be formed of similar materials with similar properties. The press-fit method includes similar tapered angles between engaged components without the use of traditional threaded features. By omitting the threaded features, these components are easily pressed together and pulled apart while improving conductivity and rapidly dissipating residuals associated with the welding process.

Description

DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATIONRETAINING HEAD AND CONTACT TIP PRESS FIT COMPONENTS AND METHODSCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the priority benefit of U.S. Provisional Application Ser. No. 63 / 696,484, filed September 19, 2024, the contents of which are herein incorporated by reference in their entirety.TECHNICAL FIELD

[0002] This disclosure relates generally to the field of welding tools, and more specifically, to the field of contact tips and consumables for welding tools. Described herein are systems and devices for utilization in welding processes.BACKGROUND

[0003] Automated welding processes include equipment to reduce human interaction during the welding application within a high production manufacturing environment. There are many advantages for automated welding applications and some of these include: increased safety by minimizing human involvement, increased productivity, increased quality, and increased repeatability.

[0004] The metal inert gas (MIG) welding process, a gas metal arc welding process, uses disposable components as part of the process. These components are known as consumables. Consumables are materials used to produce a weld. Some of these consumables are the electrode (weld wire) and a shielding gas(s) mixture. Other welding consumables are specific components such as a contact tip, a retaining head, and a gas nozzle. For example, conventionally, brass is used as the material for a retaining head, because it is easily machinable, the hardness level can withstand threads, and it is electrically conductive. The current practice uses consumables made from copper, or copper alloys, and brass. In many instances, the retaining head is made from brass and is fastened to a welding torch (gooseneck) by a threaded fastening method. The contact tip, made from a copper or copper alloy, is also threaded into the brass retaining head.

[0005] While these materials for the components are all considered consumables, they are treated differently and have different levels of importance. The welding contact tip is a vitally important component in any MIG welding process. The importance of a contact tip in a welding application is to energize the wire electrode as it passes through the contact tip with either aDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION positive or negative electrical charge. In automated welding applications, the contact tip also has the responsibility to accurately guide the wire electrode to the targeted weld joint.SUMMARY

[0006] In some aspects, the techniques described herein relate to a component for welding, including: a contact tip configured to be received into a retaining head of a welding torch, the contact tip including: a walled feature that is threadless, wherein the walled feature mates with a wall of the retaining head to secure the retaining head to the contact tip; and a first highly conductive material with similar thermal expansion characteristics as a material of the retaining head.

[0007] In some aspects, the techniques described herein relate to a method to interlock welding components including: applying a substantially parallel and direct press force to engage an interference area of a contact tip with an orifice defined by a retaining head, the orifice having a complementary interference area; and securely connecting the contact tip in the retaining head.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] The foregoing is a summary, and thus, necessarily limited in detail. The above-mentioned aspects, as well as other aspects, features, and advantages of the present technology are described below in connection with various embodiments, with reference made to the accompanying drawings.

[0009] FIG. 1 shows a side view of separated components of a torch assembly, in an embodiment.

[0010] FIGs. 2A-2C show a side view, a side cross-sectional view, and a side perspective view, respectively, of the retaining head or gas diffuser and relevant features, in an embodiment.

[0011] FIGs. 3A-3C show a side view, a side cross-sectional view, and a side perspective view, respectively, of a new welding contact tip design with geometrical features that provide the capability to press fit the contact tip to interlock with the retaining head, in an embodiment.

[0012] FIGs. 4A-4C show a side perspective view, a side cross-sectional view, and a detailed side cross-sectional view, respectively, of an assembly including a weld torch and various torch components, in an embodiment.

[0013] FIGs. 5A-5D show side perspective views of a weld torch service station designed to clean a weld torch and replace a contact tip automatically, in an embodiment.DOCKET NO. 0178-700.600 INTERNATIONAL PATENT APPLICATION

[0014] FIGs. 6A-6B show side perspective views of a torch maintenance practice utilizing a reamer and application of anti-spatter solution, in an embodiment.

[0015] FIGs. 7A-7B show side perspective views of a service station to install a new contact tip and perform a wire cutting procedure, in an embodiment.

[0016] FIGs. 8A-8B show side perspective views of an automated service to remove a slip-on style gas nozzle and replace the same slip-on gas nozzle, in an embodiment.

[0017] FIGs. 9A-9B show side perspective views of an automated service to remove a used contact tip that was fastened by a press fit method in an embodiment.

[0018] FIGs. 10A-10B show charts of force data supporting the press fit method in an embodiment. FIG. 10A shows data results that resulted from new samples being pressed together and pulled apart at various forces. FIG. 10B shows data results using samples that had already been used and are not classified as new samples. These samples have already been exposed to external stresses as a result of the first test.

[0019] FIGs. 11A-1 ID show charts of force data supporting the press fit method under cyclical heat and cooling conditions. FIG. 11A shows data compiled from a cyclical heating test. These components were pressed together at ambient temperature, heated to an elevated temperature, then cooled back to ambient temperature when pulled apart. FIG. 1 IB shows data compiled from another thermal condition where the retaining head was preheated to an elevated temperature. The contact tip was at ambient temperature when the samples were pressed together. The pressed sample was heated to elevated temperature and then cooled back to ambient temperature. FIG. 11C shows a thermal condition where the retaining head was at an elevated temperature when a contact tip at ambient temperature was pressed into the retaining head. The pressed sample was heated to an elevated temperature then pull apart while still at an elevated temperature. FIG. 1 ID shows a thermal condition where both components were at an ambient temperature when pressed together. The pressed assembly was then heated to reach an elevated temperature and pulled apart while still at an elevated temperature.

[0020] The illustrated embodiments are merely examples and are not intended to limit the disclosure. The schematics are drawn to illustrate features and concepts and are not necessarily drawn to scale.DETAILED DESCRIPTIONDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0021] The foregoing is a summary, and thus, necessarily limited in detail. The above-mentioned aspects, as well as other aspects, features, and advantages of the present technology will now be described in connection with various embodiments. The inclusion of the following embodiments is not intended to limit the disclosure to these embodiments, but rather to enable any person skilled in the art to make and use the claimed subject matter. Other embodiments may be utilized, and modifications may be made without departing from the spirit or scope of the subject matter presented herein. Aspects of the disclosure, as described and illustrated herein, can be arranged, combined, modified, and designed in a variety of different formulations, all of which are explicitly contemplated and form part of this disclosure.

[0022] The threads in a retaining head should withstand wear of multiple contact tips. Many contact tips used in automated welding applications are made from copper with chromium and zirconium as alloying elements. These contact tips also contain threads compatible with the retaining head. However, the threads machined in a copper alloy, of the contact tip, are not as durable and are susceptible to becoming deformed due to the softness property of copper. The devices described herein solve this technical problem with a technical solution. At least one of the technical solutions provided herein is a contact tip with a press fit connection that is more durable and not susceptible to deformation of a threaded connection for mating with the retaining head.

[0023] As a wire passes through the contact tip, the wire is prone to wearing out the inner diameter of the contact tip; in many cases, the inner diameter becomes oval-shaped. Oval-shaped orifices tend to reduce accuracy of wire placement in robotic welding applications. Furthermore, as the inner diameter of the contact tip, a tubular feature, degrades, micro-arcing can occur on the inner walls of the tip. Micro-arcing leads to poor conductivity between the electrode wire and the contact tip. Poor conductivity can cause other failure modes such as a bumback or poor arc stating procedures. As this contact tip begins to degrade, it can cause inconsistencies in the welding process that can jeopardize weld quality and could result in production downtime.

[0024] Another failure mode associated with consumables is the accumulation, or build up, of foreign debris inside the weld nozzle. This debris is commonly known as weld spatter as it conventionally presents itself as a very small spherical shape when the molten metal changes state back to a solid. The spatter commonly builds up in the nozzle and on the surface of the contact tip which shortens the life of the consumables. Excessive build up can reduce shielding gas flow which contributes to poor weld quality.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0025] To combat these issues, automated systems are integrated to clean the welding torch. These cleaning systems are found in almost every robotic or automated welding machine. The cleaning frequency is determined by the welding application. The cleaning procedure increases the life of the consumables and helps to maintain quality.

[0026] However, a contact tip may still degrade from the harsh environment of welding. The cyclic heating, the weld spatter, micro-arcing, and weld wire erosion may all, or singularly, contribute to reducing the life of the contact tip. Therefore, after time, the contact tip may be manually replaced. During this time of maintenance, the robotic application is halted for an unknown and uncontrolled time resulting in loss of production, because human involvement needs to be implemented.

[0027] Automated contact tip changing systems are in existence to eliminate the human involvement during the changing procedure. The first operation in these automated changing systems removes the nozzle to allow access to the contact tip. Then a task is completed by actuating a tool to unfasten the contact tip. The tooling rotates to unthread the contact tip from the receiving head. The new contact tip is positioned in the receiving head. Because the fastening method utilizes threaded components, the device rotates and fastens the contact tip in the retaining head; conventionally, after a preset torque has been met. The nozzle is replaced back on the retaining head. The technology used to execute these complex procedures is costly and poses difficulty in automated applications. End users often purchase a cleaning system and then elect whether they should invest in a complex and costly automated changing system.

[0028] At least one technical solution to the above technical problems is a system designed to clean and change the contact tip using simple practices that does not require unnecessary technology. A method to fasten a welding contact tip by utilizing a press fit, or interference fit, by force or friction can simplify the technology needed to automate this process. A direct, substantial force applied to the contact tip in parallel with a corresponding orifice defined as a tapered cylindrical wall within the retaining head is a sufficient method of securing the components. Thus, a tapered cylindrical wall that is threadless to simplify fastening of the contact tip to the retaining head may provide a technical solution to the above technical problems. With eliminating the threads on the contact tip and in the retaining head, the retaining head can be made of like materials with the same mechanical and thermal properties as the contact tip. A method to press a MIG welding contact tip into a retaining head, of similar material, can significantly simplify theDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION automated contact tip changing system because of threadless components. An automated system designed to clean the contact tip using a traditional process combined with a process to change a welding contact tip using a press fit method may lower the capital cost of the automated system. This system may also remove human involvement for manually changing the contact tip of the robotic welding processes, which is found at many high production fabrication manufacturers. A fully automatic service station capable of cleaning and changing welding consumables may also increase operator safety by removing the human involvement by less intervention with automated equipment. A fully automatic service station may also increase machine downtime by automating a process that is currently being executed manually.

[0029] A welding torch system for servicing the welding torch of an automated welding process is described below. The systems and methods function to increase productivity by reducing machine downtime, reducing human intervention with the machine, and maintaining higher quality products. The systems and methods described herein may benefit highly productive industrial manufacturers that utilize automated welding procedures as a solution. The systems and methods described herein combine the automated cleaning process of the welding components with an automated tip changing process. The automated changing process may use a press fit method when interlocking the contact tip and the retaining head.

[0030] The threaded method between a contact tip and diffuser poses many difficulties in automation. The aligning of threads and torque sensing are two of the larger factors when designing an affordable device to automatically replace a welding contact tip.

[0031] Thus, a press-fit or interference-fit between contact tip and retaining head reduces cost and technology needed to automatically change the contact tip and supports factors that extend the life of the contact tip. The two separate components may be made from similar materials with similar mechanical and / or thermal properties. Such properties, or characteristics, include, but are not limited to, hardness, modulus of elasticity, coefficient of thermal expansion, energy dissipation, and highly conductive. The material most used is copper or copper alloy for both mating components in the welding applications. Engagement between the contact tip and a retaining head may include a wall with a taper to self-align the two interlocking components. The taper ensures a maximum interference fit between the two components when being pressed. The contact tip is designated as the male component while the retaining head is designated as the female component. However, the press-fit method is not limited to a specific designation betweenDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION interlocking components. An about 2-degree to about 8-degree; about 2-degree to about 4-degree; about 2-degree to about 6-degree; about 4-degree to about 8-degree; about 6-degree to about 8- degree; about 4-degree to about 7-degree; about 2-degree to about 3-degree; about 3-degree to about 4-degree; about 4-degree to about 5-degree; about 5-degree to about 6-degree; about 6- degree to about 7-degree; about 7-degree to about 8-degree; etc. taper angle can provide sufficient alignment between mating components while still maintaining a secure connection to meet the conductivity requirements.

[0032] During any wire fed welding application, significant heat is produced as the wire is being melted and transferred to the work piece. The contact tip is closer to the welding arc, responsible for melting the wire, than the retaining head. For this reason, the contact tip, being a tubular member, can expand within the walls of the retaining head. This thermal expansion can assist in securing the contact tip to the retaining head. Thermal expansion can also promote better electrical conductivity between the retaining head and the contact tip. Using materials made of copper or copper alloys, the thermal expansion of the retaining head can be no greater than the contact tip, unlike the prior art. A retaining head comprising a copper material or copper alloy with a coefficient of thermal expansion at about 9.9 xlO'6in / (in °F) and a contact tip comprising copper or copper alloy have similar thermal expansion characteristics, allowing the press fit method to be a sufficient interlocking method in cyclic heating environments, such as welding. For example, the retaining head may be made from a copper alloy, such as Tellurium Copper (TeCu). Tellurium is added to the copper to make copper easier to machine due to the softness of pure copper, yet maintaining highly conductive properties. The contact tip may comprise copper with chromium and zirconium as alloying elements. This copper alloy is abbreviated at CuCrZr and is commonly used in contact tips in automated welding applications. An added benefit of the retaining head comprising copper or copper alloy, such as TeCU, is the ability to dissipate heat at a faster rate than the current practice. The intense heat from welding tends to degrade the life of a welding contact tip. Dissipating the heat from the contact tip may increase the lifespan of a contact tip.

[0033] The simplicity of this design is optimal for automated welding applications. For an automated service designed to change the contact tip, operations to pull off the old contact tip and press on a new contact tip yields a simpler process with less failure modes when compared to traditional threaded practices.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0034] An embodiment of a method includes effectively cleaning a torch nozzle automatically. The method may include a reaming system, an anti-spatter spray, and a wire cutting operation. The reaming system is designed to remove foreign debris, known as weld spatter, that accumulates on the consumables. The anti-spatter operation may apply a solution to the welding consumables to help reduce the rate at which the weld spatter, the foreign debris, may accumulate on the components. The wire cutting operation may trim, or cut, excess wire protruding through the contact tip. The conventional procedure is for an automated machine (i.e., robot) to move to the reaming station to execute the cleaning process. A pneumatic clamp constrains the nozzle of the welding torch while a rotary motor advances a reamer cutting blade inside the nozzle. The reamer blade removes welding spatter accumulation on the inside of the nozzle. The automated machine then advances to the anti-spatter spray station. An air and liquid solution are mixed and sprayed inside the nozzle. The purpose of the anti-spatter spray is to coat the surface of the consumables to mitigate the build-up of weld spatter. The automated machine may feed wire out of the contact tip and move into position for the wire cutting operation. The purpose of this operation is to condition the wire to the correct length and provide a sharp tip to contact the work piece for improved arc starting.

[0035] An embodiment of a method includes effectively changing the contact tip automatically. The procedure may use similar operations as the cleaning procedure by utilizing similar stations. The method may include completing execution of the process at the reaming station. The reaming station may clean the inside of the nozzle by removing excessive spatter build up. The method may include executing the wire cutting process to trim the wire. After the wire has been cut, the automated machine may retract the wire into the torch in preparation for tip removal.

[0036] The automated machine may move over to another operation which includes automatically removing the nozzle. Removing the nozzle from the retaining head can expose the contact tip. For example, the nozzle may be pulled off the retaining head by using slip-on style nozzles to simplify the automated procedures. The torch may be mechanically constrained by a pneumatic clamp. Another actuating cylinder slide can advance and constrain the nozzle. Once constrained, the cylinder slide can retract and pull off the slip-on style nozzle automatically. The automated machine torch is then released and can proceed to the next operation.

[0037] With the consumables exposed, the automated machine may move over to the station to automatically remove the contact tip. This automatic operation may include pneumaticallyDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION clamping on designed geometrical features on the retaining head or gas diffuser. Clamping can constrict and align the torch for the operation. Another pneumatic clamp can advance to grasp other designed geometrical features on the welding contact tip. When the contact tip is constrained by the clamp, the advanced slide may retract to remove the contact tip from the retaining head automatically. Disassembling the contact tip may use a direct and parallel force in the opposite direction as the press force. This parallel force in the opposite direction is described herein as a retracting force or pull force. The disassembling extraction force may be expected to be about 25% to about 75% of the insertion force, or press force, depending on welding application procedures. When the tip has been removed from the retaining head, the tip may be exposed in a container. The clamp can be released from the retaining head.

[0038] A new contact tip may be automatically pressed in the retaining head. For example, the retaining head may be pneumatically clamped on geometric features of the retaining head to constrain the weld torch of the automated machine. Another clamp can advance a new contact tip from a magazine and press the tip into the constrained retaining head automatically. The press force may be application dependent but may be no less than about 200 pounds to about 250 pounds of force to accommodate most welding applications. A wall (i.e., walled feature) of the contact tip may be complementary to a wall (i.e., walled feature) of the retaining head, containing corresponding threadless walls between both components (e.g., the contact tip and the retaining head). In some embodiments, both of the walls of the contact tip and the retaining head may be tapered. In some embodiments, one of the walls of the contact tip and the retaining head is tapered. In some embodiments, a portion of a wall of of the contact tip and / or a portion of a wall of the retaining head may be tapered. In some embodiments, one or more of the wall of the retaining head and the wall of the contact tip are tapered threadless cylindrical walls. The walled (e.g., flat walled and / or tapered wall) feature areas are the designed interference areas. The interference area is responsible for securing the connection between the contact tip and the retaining head and completing an electrically conductive path between both components. Once the new tip has been pressed into the retaining head, the retaining head may be released by the automated machine (i.e., robot). The taper angle of the threadless cylindrical outer wall of the contact tip, also described herein as the interference area of the contact tip, and the threadless cylindrical inner wall of the orifice of the retaining head, a complementary interference area of the retaining head, maybe be between about 2-degrees and about 8-degrees to accommodate most automated applications. TheDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION interference area and complementary interference area may be between about 2-degree to about 8- degree; about 2-degree to about 4-degree; about 2-degree to about 6-degree; about 4-degree to about 8-degree; about 6-degree to about 8-degree; about 4-degree to about 7-degree; about 2- degree to about 3-degree; about 3-degree to about 4-degree; about 4-degree to about 5-degree; about 5-degree to about 6-degree; about 6-degree to about 7-degree; about 7-degree to about 8- degree; etc.

[0039] In some embodiments, the automated machine may move back to the station containing the gas nozzle. The automated machine torch may become constrained using the same method before, while the cylinder slide containing the nozzle may be advanced and mechanically fixed to the retaining head automatically. The grasping of the nozzle and the constraints of the torch may be disengaged, allowing the automated machine to continue. The wire may be fed back through the contact tip to prepare for welding.

[0040] To better comprehend the method, system, and devices, drawings are attached to provide proof of concept. The drawings are not necessary to scale, but their purpose is to provide a visual aid in describing components of a weld torch and certain consumables. The drawings will also provide detail in the press-fit interlocking connection between retaining head and contact tip.

[0041] FIG. 1 shows various components of a welding torch system, in an embodiment. Part of the torch assembly 1 known as the gooseneck conventionally comprised as aluminum and is electrically insulated from the inner mating component containing copper threads 2. In some embodiments, the conductive member of the gooseneck 2 comprises a threaded component that is tubular where a steel liner 3 runs through the weld torch 1. The retaining head 4, or gas diffuser, may be made of tellurium copper alloy (TeCu) and is mechanically fastened to the copper threads on the gooseneck 2. The contact tip 5 may be made of copper chromium zirconium alloy (CuCrZr) and may be fastened into the retaining head 4 by utilizing a press fit method. The gas nozzle 6 may be fastened to the retaining head 6 and is electrically insulated on the outside.

[0042] FIGs. 2A-2C illustrate, in an embodiment, a press fit designed retaining head 4. The retaining head 4 may comprise copper with tellurium as an alloy, a highly conductive copper alloy material. TeCu may assist in dissipating energy in the form of heat faster than conventional practices and / or materials, which use brass. In FIG. 2A the component defines a slotted feature 7 to hold an O-ring (not shown) for an airtight seal. A slot 8 may be included for placing a retaining ring (not shown), used to fasten the slip-on style gas nozzle 30 (see, e.g., FIG. 85B). AnotherDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION geometrical feature 9 (e g., groove, partial or full depressed ring surface, etc.) may be used to clamp and constrict the retaining head when changing out the contact tip. FIG. 2B, a cross-sectional view of FIG. 2A, shows a wall 11 that may be one or more of inner, threadless, tapered and / or cylindrical and is the interference area of the retaining head 4. In some embodiments, a tapered angle a’ of the cylinder wall 11 may be between about 2 degrees to about 8 degrees to assist in alignment and securing the contact tip to the retaining head 4 (see, e.g., FIG. 1). In some emboidments, the wall 11 (i.e., walled feature) may not be tapered. Retaining head 4 may include a thread 14 interface mated to the threads of gooseneck 2. A tubular feature 12 allows weld wire to transfer through the retaining head and a pocket 13 designed to have the liner 3 reside when attached to the gooseneck 2 (see, e.g., FIG. 1). The retaining head 4 may include mating threads 14 to be fastened to the gooseneck 2 component of the weld torch 1. As shown in FIG. 2C, the retaining head 4 component may include a geometric shoulder 16 to act as a positioning feature when locating the gas nozzle 30 (see, e.g., FIG. 5B). The orifice 15 is sized and / or shaped to receive the contact tip 5 (see, e.g., FIG. 1).

[0043] FIGs. 3A-3C provide an embodiment of a contact tip 5 designed to be fastened by means of a press fit method to the retaining head 4 (e.g., of FIGs. 2A-2C). In some embodiments, a contact tip 5 may comprise copper with chromium and zirconium as alloying elements. FIG. 3A shows the tip containing a small radius 17 to assist in alignment with the retaining head 4 (see, e.g., FIG 1). The contact tip 5 component has a designed interference area 18 to mate with the wall 11 (see, e g., FIG. 2B) of the orifice 15 (see, e g., FIG. 2C) of the retaining head 4. In some embodiments, the interference area 18 is a wall (i.e., walled feature) that may be one or more of tapered, threadless, and / or cylindrical which corresponds to (e.g., mates) the wall 11 of the retaining head 4. A taper angle b’ between about 2 degrees and about 8 degrees may be sufficient for most applications. The taper angle b’ of the contact tip 5 may assist in alignment with the retaining head 4 and promote a secure connection between the two components. The contact tip 5 also contains a geometric feature 19 for use as a mechanical constraint to assist in removal of the contact tip 4. The cross section of FIG. 3A is shown in FIG. 3B. The contact tip 5 contains a chamfer angle 21 to self-guide a weld wire into the inner tube 20 where the wire becomes electrically charged. FIG. 3C shows the circular orifice 22 where the weld wire may exit the contact tip 5.

[0044] The assembled components of the weld torch 1 is shown in FIG. 4A, to be mounted to the end of a manufacturing robot. FIG. 4B shows a thread 23 which securely fastens the retainingDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION head 4 to the torch gooseneck 2. The connection between the thread 23 of the gooseneck 2 and the thread 14 of the retaining head 4 is responsible for transferring electrical energy from the welding torch 1 to the retaining head 4. FIG. 4C is a detailed view of the cross-sectional view of FIG. 4C. The retaining head 4 has a designed pocket 24 to allow shielding gas to be passed through the retaining head 4 and expelled from the retaining head 4 through orifice 10 of FIG. 2A. There is a void 25 defined between the contact tip 5 and the receiving pocket 24 of the retaining head 4. This void 25 promotes successful press fit practices to ensure interference fit is sufficiently occurring in the interference area 26 (i.e., the contacting surfaces of the contact tip 5 and retaining head 4), while minimizing or eliminating contact in other areas between the contact tip 5 and the retaining head 4. The interference area 26 is also responsible to transfer electrical current from the retaining head 4 to the contact tip 5. As such, if there is contact between the retaining head 4 and the contact tip 5 outside of the interference area 26, the welding process may not be repeatable, and there may be burnback, or there may be an increased accumulation of weld spatter or may result in a poorly secured connection between mating components. The electrically conductive path is completed through the connected interference area 26 between mating components (i.e., retaining head 4 and contact tip 5). The design of the press fit features a maximum depth 27 of press to ensure repeatability of the welding process and assembly of components. Fastening the retaining head 4 to the contact tip 5 to the maximum depth 27 of press creates the void 25 and the designed interference area 26 based on the taper of each of the retaining head 4 and the contact tip 5 and a maximum force utilized in press-fitting the retaining head 4 and the contact tip 5. The assembly of the weld torch 1 contains a pocket 28 designed to seat the liner through which the weld wire is transferred.

[0045] FIGs. 5A-5D show an embodiment of a weld torch service station 29 designed to clean a weld torch 1 and replace a contact tip 5 automatically. This service contains a station 29 with the purpose to clean the nozzle 30 (see, e.g., FIG. 5B) using conventional practices and spray anti spatter by means of conventional practices; and another station 31, with a purpose of removing a slip-on style gas nozzle 30. FIG. 5C is a detailed view of FIG. 5D and highlights a station 31 comprising operations to remove a used contact tip 5, and a station 32 to press in a new contact tip 5.

[0046] FIGs. 6A-6B show a torch maintenance practice utilizing a reamer and application of anti-spatter solution. As shown in FIG. 6A, the system includes a rotary motor 34 and a reservoirDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION of anti-spatter solution 33. FIG. 6B provides a more detailed view of FIG. 6A. The cleaning reamer bit 36 is a cutting tool which is advanced by an actuator 35 into the gas nozzle 38. The reamer bit 36 is designed to remove foreign debris that accumulates on the surface of the consumables. The gas nozzle 30 (see, e.g., FIG. 5B) is constrained by a clamping mechanism 43 to hold the weld torch 1 during the cleaning process and align the torch 1 with an aligner 37 to the reamer bit 36. The anti-spatter solution in a container 33 travels through a hose 40 and is mixed with pressurized air 41. The solution is expelled through a small orifice 42 and applies a coat on welding consumables when the robot is in place over the orifice 42. This solution helps prevent the accumulation of weld spatter.

[0047] FIG. 7A shows an embodiment of a service station 32 (see, e.g., FIG. 5C) to install a new contact tip 5 and perform a wire cutting procedure. FIG. 7A shows a magazine style holder 45 which contains multiple new contact tips 5 which are driven up into the retaining head 4 by a mechanical actuator 44.

[0048] FIG. 7B shows a detailed view of FIG. 7A. With the welding torch 1 in position 54 and constrained by a mechanical fixture 46, a new contact tip 47 is pressed into the retaining head 48. The actuator 49 is designed to extract a contact tip 47 from the magazine style holder 45 and press the new contact tip 47 into the retaining head 48. The actuator 49 may apply a direct, substantial force parallel with the retaining head 48 to secure the press fit connection. The retaining head 48 contains an inner orifice (see, e.g., FIG. 2C) to define the geometry of the press fit connection. The robot may then move and engage weld torch 1 to the cutting station 55 and the weld wire 53 may be cut by the actuating cutting blade 51 and the fixed blade 52 when a mechanical actuation is triggered 50. The cutting operation may cut any excessive wire protruding from the contact tip 47.

[0049] FIGs. 8A-8B show an embodiment of an automated service to remove a slip-on style and replace the same slip-on gas nozzle 30 (see, e g., FIG. 5B). FIG. 8A shows a mechanical actuator 56 that positions another actuator 58 into a position to grasp the gas nozzle 30. The welding torch 1 is constrained by a clamping mechanism 57. FIG. 8B shows a detailed view of FIG. 8A. FIG. 8B shows the slide 60 which positions a mechanical gripper 59 to constrain the gas nozzle 30. The torch being in position 63 and is fixed when an actuating detail 62 engages the torch 63 and is constrained to a mating interface 61.

[0050] FIGs. 9A-9B shows an embodiment of an automated service to remove a used contact tip 5 that was fastened by a press fit method. FIG. 9A shows the welding torch in position 64.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATIONContainer 66 collects and manages used contact tips 5. A more detailed view is shown in FIG. 9B where the retaining head 4 is fixed by an actuating detail 71 which constrains the retaining head to a mating interface 72 when a mechanical clamp 70 is engaged. A slide 69 advances to position when cylinder 65 in FIG. 9A is engaged. A mechanism 68 designed to grip the contact tip 5 may constrain the contact tip 5 when a mechanical force 67 is energized. When the contact tip 5 is constrained, a mechanical force to pull off the contact tip 5 is achieved when contact tip 5 is pulled away from the retaining head 4.

[0051] FIG. 10A shows push / pull force test data in a chart. The testing was conducted at ambient temperature. The test was completed using newly machined retaining heads (diffuser) and new contact tips. The retaining head comprised copper with tellurium as the main alloying element. The contact tip comprised of copper with chromium and zirconium as alloying elements. Both tapered cylindrical interference areas were machined with a four-degree taper and a micro finish level eight, or a smooth non-coarse finish. A total of five samples were pressed at a given force then pulled apart with a retractive force. The retracted force was recorded. Each sample was tested five times per given press force. The press force started at about 100-pounds of force and incremented up to about 225-pounds of force. The data summary provides average retracting force of each trial, a range in the supporting data, and a percent change between press force and retracting force.

[0052] FIG. 10B shows a second chart including data recorded while conducting the same test using the same components as the initial test shown in FIG. 10A. However, in contrast to the components used in FIG. 10A, the components used in FIG. 10B have already been pressed and pulled which results in a work hardened surface known as plastic deformation. A condition where the metallurgical structure has been hardened due to a mechanical stress. The results of the second test in FIG. 10B shows a press force and a retracting force that still support a press fit method of interlocking the retaining head and contact tip.

[0053] The purpose of conducting this test was to determine the percent change between an insertion force and a retracting force. Factors that changed during this test was the force applied during the press and how the force effected the percent change when pulling the components apart.

[0054] A conventional automated wire feeder can fail when excessive amperages are required for the electric motor to push weld wire through a contact tip. For example, if the welding wire becomes fused to the contact tip, known as a bumback, the wire feeder could fail because it hasDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION failed to push the weld wire through the contact tip. The terminology of the fault might be different between manufacturers, but excessive torque and amperages were reached when attempting to push the wire through the tip. The amount of force on the wire to fault the wire feeder is approximately 5 pounds, but it is likely variable depending on welding applications and equipment manufacturers. Accordingly, the minimum press force to retain a contact tip should be no less than about 5-pounds. If the designed pull force is less than about 5-pounds, the wire feeder may be capable of pushing the contact tip out of the retaining head. To find a targeted retracting force required to prove the press fit concept, the minimum required force is multiplied by a factor of safety of 10. This is a conventional rule in manufacturing to create a robust process.

[0055] For example, in an instance of a retracting force of about 5 pounds, up to about 50 pounds may be required (based on the equation of 5 pounds / force x 10 = 50 pounds / force). Therefore, the minimum force to pull a contact tip from the retaining may be at least about 50 pounds of force to maintain a robust press fit method of joining the contact tip to the retaining head.

[0056] The results in FIG. 10A of the test conducted show the retracting force under the Data Results 100 column. When examining the retracting forces amongst all five samples, the minimum insertion force to satisfy the targeted at least about 50 pounds of pull force requirement was an insertion force of 200-pounds.

[0057] The data shown in FIG. 10B was collected by duplicating the first testing procedure but using the same components which had become hardened after the completion of the first test. The purpose of the second test is to understand how work hardened surfaces between the mating components affect the forces needed to securely fasten them together. The Data Results 102 column shows significantly higher retracting forces when lower press forces were applied when compared to the Data Results 100 from the previous test in FIG. 10A. However, when elevated press forces were applied, about 200-pounds or more, the retracting forces were more comparable to the initial test data found on FIG. 10A. This test with supporting data suggests that a work hardened surface in the interference zone can support the press fit method between the contact tip and retaining head.

[0058] Furthermore, the Data Summary columns in FIG. 10A and FIG. 10B provide the average, range, and percent change of the corresponding test. The percent change moderately varied between testing samples and the insertion force between both charts. Although the data shows that about a 200-pound press force can satisfy the targeted about 50-pound retracting forceDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION requirement, cyclical heating tests were conducted using about 225-pounds of press force because of the varying percent change among the conclusion of these tests.

[0059] FIGs. 11A-1 ID each show a chart of multiple test results supporting the effectiveness of the press fit method under cyclical heating environments. The thermal conditions are designed to simulate welding conditions where components are rapidly heated to elevated temperature and cooled back to ambient temperatures. Each thermal condition varies based on different thermal scenarios found in automated welding manufacturing. Using components comprising similar materials with similar coefficients of thermal expansion are supported in the data results shown in FIGs. 1 1A-1 1D.

[0060] The chart shown in FIG. 11A supports the press fit method when the retaining head (diffuser) and the contact tip are pressed together at room temperature with about 225-pounds of force. The pressed components were placed into a lab oven and heated until temperatures in the lab oven reached about 400 °F. The component was then pulled from the heat source and allowed time to cool to room temperature. Once the sample reached ambient temperature, the sample was pulled apart and the retracting force was recorded. A total of five samples were observed and each sample was tested five times.

[0061] This specific thermal test was designed to simulate automated weld equipment that had been idle long enough for consumables to reach ambient temperature. A new contact tip was pressed into the retaining head to begin a welding cycle. After the welding cycle was completed, the welding equipment had returned to an idle state where the contact tip and retaining head had returned to ambient temperature.

[0062] The chart shown in FIG. 1 IB shows testing data that was conducted to observe another thermal condition where the retaining head (diffuser) was preheated up to about 400 °F. The contact tip was at room temperature when the contact tip was pressed into the preheated retaining head under about 225-pounds of force. The assembly was then placed into the lab oven and heated up to about 400 °F. When elevated temperatures were reached, the Data Results 110 show the components were removed from the oven and allowed to cool to ambient temperature. The retracting forces were recorded and shown in FIG. 1 IB. A total of five assembled units underwent this testing cycle occurred five times.

[0063] This specific thermal test was designed to simulate a condition where a new contact tip was pressed into a retaining head on welding equipment that was actively in production and atDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION elevated temperatures. The pressed components were allowed time to cool to ambient temperature to further show how the press fit condition would be sufficient when a machine had become idle. The retaining head made from a copper alloy TeCu may dissipate the heat at a faster rate which may extend the life of the contact tip. The Data Results 112 in FIG. 1 IB shows that pressing the contact tip into a retaining head while each component is at different temperatures and pulling them apart at the same ambient temperature still satisfy the requirements of the press fit method.

[0064] The chart shown in FIG. 11C provides an example of another thermal condition, where the retaining head (diffuser) was preheated to an elevated temperature of up to about 400 °F. The contact tip at room temperature was pressed into the heated retaining head at about 225-pounds of force. The pressed components were placed into the lab oven and heated up to about 400 °F. The pressed component was pulled from the oven and immediately pulled apart while components were still at elevated temperatures. A total of five assembled components were pressed together and was tested five times each for showing the Data Results 114 of FIG. 11C.

[0065] This thermal test was designed to simulate automated welding equipment that is active and consistently at elevated temperatures. This condition is the most common condition of which the changing of consumables can occur. The retaining head can contain excessive residual heat from the high productivity welding process when a new contact tip, at ambient temperature, is pressed into the retaining head. The welding equipment returns to the welding and is exposed to significant heat. Over time, the contact tip begins to degrade and needs to be replaced. The contact tip and retaining head still contain residual heat at elevated temperatures when the tip is pulled from the retaining head.

[0066] The Data Results 116 provided in the chart shown in FIG. 1 ID shows an example of a thermal condition where both the retaining head (diffuser) and the contact tip were pressed together with about 225-pounds of force at room temperature. The components were placed into the lab oven and heated up to about 400°F. The samples were removed from the oven and pulled apart while being at an elevated temperature. A total of five samples were tested under these conditions and each sample was tested five times.

[0067] Thi s test was designed to simulate thermal conditions where welding equipment had been idle and both components are pressed together at ambient temperature. The welding process begins, and components are exposed to significant heat from the welding process. The contact tip begins to degrade, and the tip is pulled from the retaining head while at elevated temperatures.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0068] The results of the thermal testing show that a press fit method using components made from a material using similar coefficients of thermal expansion can maintain a secured connection between the contact tip and retaining head. The press fit method may maintain a secure connection through cyclical heating conditions when press forces are between about 200 pounds of force to about 250 pounds of force. The testing examples show the results of a press force of about 225- pounds with about a 4-degree taper angle and a smooth surface for the designed interference fit area will withstand the cyclical heating environment associated with automated welding.EXAMPLES

[0069] Example 1. A component for welding, comprising: a contact tip configured to be received into a retaining head of a welding torch, the contact tip comprising: a walled feature that is threadless, wherein the walled feature mates with a wall of the retaining head to secure the retaining head to the contact tip; and a first highly conductive material with similar thermal expansion characteristics as a material of the retaining head.

[0070] Example 2. The component for welding of example 1, wherein the wall of the retaining head comprises a threadless orifice with a tapered cylindrical wall comprising a second highly conductive material.

[0071] Example 3. The component of any one of the preceding examples, but particularly example 1, wherein the retaining head comprises a material with similar mechanical and thermal properties as the contact tip.

[0072] Example 4. The component of any one of the preceding examples, but particularly example 1, wherein an inner diameter of the wall of the retaining head is threadless and is configured to be secured to the contact tip through a press fit connection.

[0073] Example 5. The component of any one of the preceding examples, but particularly example 1, wherein an outer diameter of the wall of the contact tip is threadless and is configured to be secured to the retaining head through a press fit connection.

[0074] Example 6. The component of any one of the preceding examples, but particularly example 1, wherein an interference area of the contact tip and an orifice of the retaining head each comprise copper or a copper alloy material with high electrical conductivity and mechanical properties.

[0075] Example 7. The component of any one of the preceding examples, but particularly example 6, wherein the orifice of the retaining head comprises copper with tellurium as an alloyingDOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION element, and the interference area of the contact tip comprises copper with chromium and zirconium as alloying elements.

[0076] Example 8. The component of any one of the preceding examples, but particularly example 6, wherein a surface of the interference area has a taper of about 2 degrees to about 8 degrees for alignment and for securing of the retaining head to the contact tip.

[0077] Example 9. The component of any one of the preceding examples, but particularly example 1, wherein the contact tip comprises one or more of: copper, copper alloy, or another highly conductive material used in a welding process.

[0078] Example 10. The component of any one of the preceding examples, but particularly example 1, wherein the retaining head is made from a similar copper, copper alloy, or any other highly conductive material used in a welding process.

[0079] Example 11. The component of any one of the preceding examples, but particularly example 1, further comprising a void between the contact tip and a receiving retaining head.

[0080] Example 12. The component of any one of the preceding examples, but particularly example 1, further comprising an electrically conductive path through an interference area of the contact tip received by the retaining head.

[0081] Example 13. The component of any one of the preceding examples, but particularly example 1, wherein the contact tip comprises a copper or a copper alloy configured to increase energy dissipation to extend a life of the contact tip.

[0082] Example 14. The component of any one of the preceding examples, but particularly example 1, wherein a connection between the retaining head and the contact tip is configured to be maintained through cyclical heating conditions when press forces are between about 200 pounds of force to about 250 pounds of force.

[0083] Example 15. The component of any one of the preceeding examples, but particularly example 1, wherein the contact tip is work hardened.

[0084] Example 16. A method to interlock welding components comprising: applying a substantially parallel and direct press force to engage an interference area of a contact tip with an orifice defined by a retaining head, the orifice having a complementary interference area; and securely connecting the contact tip in the retaining head.

[0085] Example 17. The method of example 16, wherein the retaining head comprises a material with similar mechanical and thermal properties as the contact tip.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0086] Example 18. The method of any one of the preceding examples, but particularly example 16, wherein an inner diameter of a cylindrical wall of the retaining head is threadless and is configured to be secured to the contact tip through a press-fit connection.

[0087] Example 19. The method of any one of the preceding examples, but particularly example 16, wherein an outer diameter of a cylindrical wall of the contact tip is threadless and is configured to be secured to the retaining head through a press-fit connection.

[0088] Example 20. The method of any one of the preceding examples, but particularly example15, wherein the interference area of the contact tip and the orifice of the retaining head each comprise copper or a copper alloy material with high electrical conductivity and similar mechanical and thermal properties.

[0089] Example 21. The method of any one of the preceding examples, but particularly example 20, wherein the orifice and threadless tapered cylindrical wall of the retaining head comprise copper or copper alloy material, and the interference area of the contact tip, a corresponding threadless tapered cylindrical wall, comprises copper or copper alloy material.

[0090] Example 22. The method of any one of the preceding examples, but particularly example16, wherein the interference area of the contact tip and the orifice and tapered cylindrical wall of the retaining head comprise a material having similar thermal expansion properties.

[0091] Example 23. The method of any one of the preceding examples, but particularly example 16, wherein a surface of the interference area has an about 2 degrees to about 8 degrees taper for alignment and securing of the retaining head to the contact tip.

[0092] Example 24. The method of any one of the preceding examples, but particularly example 16, further comprising disassembling a connection between the retaining head and the contact tip by applying a second direct and parallel force in an opposite direction as the press force.

[0093] Example 25. The method of any one of the preceding examples, but particularly example 16, further comprising automatically changing the contact tip.

[0094] Example 26. The method of any one of the preceding examples, but particularly example 16, wherein the contact tip comprises one or more of copper, copper alloy, or another highly conductive material used in a welding process.

[0095] Example 27. The method of any one of the preceding examples, but particularly example 26, wherein the retaining head comprises one or more of a similar copper, copper alloy, or any other highly conductive material used in a welding process.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION

[0096] Example 28. The method of any one of the preceding examples, but particularly example 16, further comprising defining a void between the contact tip and the retaining head.

[0097] Example 29. The method of any one of the preceding examples, but particularly example 16, further comprising creating an electrically conductive path through the interference area of a connection between the contact tip and the retaining head.

[0098] Example 30. The method of any one of the preceding examples, but particularly example 16, wherein the retaining head comprises a copper or a copper alloy configured to increase energy dissipation to extend a life of the contact tip.

[0099] Example 31 . The method of any one of the preceding examples, but particularly example 16, wherein the method is configured to be used as part of an automated welding application to reduce machine downtime by removing manual user involvement when changing a welding contact tip.

[0100] Example 32. The method of any one of the preceding examples, but particularly example 16, further comprising maintaining a secure connection through cyclical heating conditions when press forces are between about 200 pounds of force to about 250 pounds of force.

[0101] References in the specification to “one embodiment,” “an embodiment,” “an illustrative embodiment,” “some embodiments,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may or may not necessarily include that particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0102] As used in the description and claims, the singular form “a”, “an” and “the” include both singular and plural references unless the context clearly dictates otherwise. At times, the claims and disclosure may include terms such as “a plurality,” “one or more,” or “at least one;” however, the absence of such terms is not intended to mean, and should not be interpreted to mean, that a plurality is not conceived.

[0103] The term “about” or “approximately,” when used before a numerical designation or range (e.g., to define a length or pressure), indicates approximations which may vary by ( + ) or ( - ) 5%, 1% or 0.1%. All numerical ranges provided herein are inclusive of the stated start and end numbers.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATIONThe term “substantially” indicates mostly (i.e., greater than 50%) or essentially all of a device, substance, or composition.

[0104] As used herein, the term “comprising” or “comprises” is intended to mean that the devices, systems, and methods include the recited elements, and may additionally include any other elements. “Consisting essentially of’ shall mean that the devices, systems, and methods include the recited elements and exclude other elements of essential significance to the combination for the stated purpose. Thus, a system or method consisting essentially of the elements as defined herein would not exclude other materials, features, or steps that do not materially affect the basic and novel character! stic(s) of the claimed disclosure. “Consisting of’ shall mean that the devices, systems, and methods include the recited elements and exclude anything more than a trivial or inconsequential element or step. Embodiments defined by each of these transitional terms are within the scope of this disclosure.

[0105] The examples and illustrations included herein show, by way of illustration and not of limitation, specific embodiments in which the subject matter may be practiced. Other embodiments may be utilized and derived therefrom, such that structural and logical substitutions and changes may be made without departing from the scope of this disclosure. Such embodiments of the inventive subject matter may be referred to herein individually or collectively by the term “invention” merely for convenience and without intending to voluntarily limit the scope of this application to any single invention or inventive concept, if more than one is in fact disclosed. Thus, although specific embodiments have been illustrated and described herein, any arrangement calculated to achieve the same purpose may be substituted for the specific embodiments shown. This disclosure is intended to cover any and all adaptations or variations of various embodiments. Combinations of the above embodiments, and other embodiments not specifically described herein, will be apparent to those of skill in the art upon reviewing the above description.

Claims

DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATIONCLAIMSWhat is claimed is:

1. A component for welding, comprising: a contact tip configured to be received into a retaining head of a welding torch, the contact tip comprising: a walled feature that is threadless, wherein the walled feature mates with a wall of the retaining head to secure the retaining head to the contact tip; and a first highly conductive material with similar thermal expansion characteristics as a material of the retaining head.

2. The component for welding of claim 1, wherein the wall of the retaining head comprises a threadless orifice with a tapered cylindrical wall comprising a second highly conductive material.

3. The component of claim 1, wherein the retaining head comprises a material with similar mechanical and thermal properties as the contact tip.

4. The component of claim 1, wherein an inner diameter of the wall of the retaining head is threadless and is configured to be secured to the contact tip through a press fit connection.

5. The component of claim 1, wherein an outer diameter of the wall of the contact tip is threadless and tapered and is configured to be secured to the retaining head through a press fit connection.

6. The component of claim 1, wherein an interference area of the contact tip and an orifice of the retaining head each comprise copper or a copper alloy material with high electrical conductivity and mechanical properties.

7. The component of claim 6, wherein the orifice of the retaining head comprises copper with tellurium as an alloying element, and the interference area of the contact tip comprises copper with chromium and zirconium as alloying elements.

8. The component of claim 6, wherein a surface of the interference area has a taper of about 2 degrees to about 8 degrees for alignment and for securing of the retaining head to the contact tip.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION9. The component of claim 1, wherein the contact tip comprises one or more of: copper, copper alloy, or another highly conductive material used in a welding process.

10. The component of claim 1, wherein the retaining head is made from a similar copper, copper alloy, or any other highly conductive material used in a welding process.

11. The component of claim 1, further comprising a void between the contact tip and a receiving retaining head.

12. The component of claim 1, further comprising an electrically conductive path through an interference area of the contact tip received by the retaining head.

13. The component of claim 1, wherein the contact tip comprises a copper or a copper alloy configured to increase energy dissipation to extend a life of the contact tip.

14. The component of claim 1, wherein a connection between the retaining head and the contact tip is configured to be maintained through cyclical heating conditions when press forces are between about 200 pounds of force to about 250 pounds of force.

15. The component of claim 1, wherein the contact tip is work hardened.

16. A method to interlock welding components comprising: applying a substantially parallel and direct press force to engage an interference area of a contact tip with an orifice defined by a retaining head, the orifice having a complementary interference area; and securely connecting the contact tip in the retaining head.

17. The method of claim 16, wherein the retaining head comprises a material with similar mechanical and thermal properties as the contact tip.

18. The method of claim 16, wherein an inner diameter of a cylindrical wall of the retaining head is threadless and is configured to be secured to the contact tip through a press-fit connection.

19. The method of claim 16, wherein an outer diameter of a cylindrical wall of the contact tip is threadless and is configured to be secured to the retaining head through a press-fit connection.

20. The method of claim 16, wherein the interference area of the contact tip and the orifice of the retaining head each comprise copper or a copper alloy material with high electrical conductivity and similar mechanical and thermal properties.DOCKET NO. 0178-700.600INTERNATIONAL PATENT APPLICATION21. The method of claim 20, wherein the orifice and threadless tapered cylindrical wall of the retaining head comprise copper or copper alloy material, and the interference area of the contact tip, a corresponding threadless tapered cylindrical wall, comprises copper or copper alloy material.

22. The method of claim 16, wherein the interference area of the contact tip and the orifice and tapered cylindrical wall of the retaining head comprise a material having similar thermal expansion properties.

23. The method of claim 16, wherein a surface of the interference area has an about 2 degrees to about 8 degrees taper for alignment and securing of the retaining head to the contact tip.

24. The method of claim 16, further comprising disassembling a connection between the retaining head and the contact tip by applying a second direct and parallel force in an opposite direction as the press force.

25. The method of claim 16, further comprising automatically changing the contact tip.

26. The method of claim 16, wherein the contact tip comprises one or more of: copper, copper alloy, or another highly conductive material used in a welding process.

27. The method of claim 26, wherein the retaining head comprises one or more of: a similar copper, copper alloy, or any other highly conductive material used in a welding process.

28. The method of claim 16, further comprising defining a void between the contact tip and the retaining head.

29. The method of claim 16, further comprising creating an electrically conductive path through the interference area of a connection between the contact tip and the retaining head.

30. The method of claim 16, wherein the retaining head comprises a copper or a copper alloy configured to increase energy dissipation to extend a life of the contact tip.

31. The method of claim 16, wherein the method is configured to be used as part of an automated welding application to reduce machine downtime by removing manual user involvement when changing a welding contact tip.

32. The method of claim 16, further comprising maintaining a secure connection through cyclical heating conditions when press forces are between about 200 pounds of force to about 250 pounds of force.

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