Guide system for non-round wire of welding systems

Abstract

A holder for attachment to a welding end assembly for welding system receives a consumable wire electrode. The wire electrode has a non-round cross-sectional shape. The end assembly features a tip having internal bore closely conforming to the cross-sectional shape of the electrode wire. The holder includes a plurality of internal rollers, and the rollers guide and orient the non¬ round wire as it passes through the holder from a wire guide cable and into the end assembly.

Description

Attorney Docket No.: 91694-171GUIDE SYSTEM FOR NON-ROUND WIRE OF WELDING SYSTEMSFIELD

[0001] This invention relates to metal fusion welding equipment and processes utilizing an electric arc, including laser welding systems, and the use of a non-round filler wire or consumable electrode to provide additional metal for forming a weld bead and joint. More specifically, the invention relates to a torch end assembly for such systems.BACKGROUND

[0002] The applicant is the developer of numerous innovations in the area of welding technologies, including; gas metal arc welding (GMAW), also known as metal inert gas (MIG) welding, metal active gas (MAG) welding, shielded metal arc welding (SMAW), gas tungsten arc welding (GTAW), flux cored arc welding (FCAW), submerged arc welding (SAW), electroslag welding (ESW), electric resistance welding (ERW), laser welding, ultrasonic welding, and other types and variations of such welding technologies. Among other areas of innovation, the applicants have discovered numerous improvements in the design, transport and equipment for consumable electrodes in the form of a filler or weld wire used in many of these processes. In systems of the above described type, filler or weld wire is fed through a welding torch to the weld arc area. The wire typically used in the past has a round cross-sectional shape. Applicants have discovered numerous advantages in the use of a non-round cross-section filler or weld wires such as those having an essentially elliptical cross-sectional profile, flattened or other non-round shapes for MIG welding and similar processes. Among other benefits, such weld wire configurations provide better electrical contact with the torch tip thereby conducting electric current to the workpiece through the weld wire with less resistance. Such advantages are described and claimed by U.S. Patent Nos. 8,878,098; and 9,440,304, and as described in the patent application published as US 2015 / 048056, which are incorporated herein by reference. Applicant has also applied non-round weld filler wire technology to welding processes not based on electrical resistance as a heat source, but instead rely on radiant energy beams such as from a laser source.Attorney Docket No.: 91694-171

[0003] While the use of non-round electrode wire is known in the prior art, there is a continued need to provide welding and welding tip systems, especially adapted for the use of such wire.SUMMARY

[0004] One of the principal advantages of the use of non-round wire is the ability to provide a precise orientation between the major and minor axes of the wire cross-section relative to the weld bead, the weld joint structure, and the direction of advancement of the weld bead during welding processes.

[0005] The present invention is related to a holder of an end assembly for use with non-round wire, and which includes rollers within the holder, which maintain an orientation of the wire as is delivered into and through the end assembly toward the contact tip.

[0006] In one aspect, a holder for attachment to a welding end assembly for welding system receives a consumable wire electrode. The wire electrode has a non-round cross-sectional shape. The end assembly features a tip having internal bore closely conforming to the cross-sectional shape of the electrode wire. The holder includes a plurality of internal rollers, and the rollers guide and orient the non-round wire as it passes through the holder from a wire guide cable and into the end assembly.

[0007] The appended drawings and description provide a description of these features.Attorney Docket No.: 91694-171BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a pictorial schematic illustration of a welding gun utilizing the end assembly in accordance with the present invention.

[0009] Figure 2A is an illustration of forming a weld using conventional prior art round crosssection electrode wire.

[0010] Figure 2B is an illustration of the depth of penetration of a weld using a weld wire having a non-round cross-section with the axes of the wire at a first orientation;

[0011] Figure 2C is an illustration of the depth of penetration of a weld using a weld wire having a non-round cross-section with the axes of the wire oriented in a second oreitnation.

[0012] Figure 3 is a perspective view of the end assembly in accordance with the present invention.

[0013] Figure 4 is a cross-sectional view through the end assembly in accordance with the present invention.

[0014] Figure 5 is an exploded view of the end assembly.

[0015] Figure 6 is a cross-sectional view of the end assembly taken along line 6-6 of Figure4.

[0016] Figure 7 is a cross-sectional view of the end assembly taken along line 7-7 of Figure 4.

[0017] Figure 8A is an exploded view of a first alternate embodiment of a diffuser in accordance with the present invention.

[0018] Figure 8B is an exploded view of a second alternate embodiment of a diffuser in accordance with the present invention.

[0019] Figure 8C is an exploded view of a third alternate embodiment of a diffuser in accordance with the present invention.

[0020] Figure 8D is an exploded view of a fourth alternate embodiment of a diffuser in accordance with the present invention.

[0021] Figure 8E is an exploded view of a fifth alternate embodiment of a diffuser in accordance with the present invention.Attorney Docket No.: 91694-171

[0022] Figure 9 is an assembled view of a holder and a gooseneck, with the holder having a plurality of internal guide rollers.

[0023] Figure 10 is an isometric view of the holder illustrating the wire that is provided from a wire guide cable.

[0024] Figure 1 1 is an isometric view of the holder illustrating the wire being fed toward the gooseneck of the end assembly.DETAILED DESCRIPTION

[0025] Within this description, the term “non-round” is used to describe welding electrode wire. This term is intended to apply to all cross-sectional shapes which are not round, including but not limited to cross-sections which are; elliptical, flattened, formed with concave or convex sides, formed with a radius of curvature which is not constant around its perimeter, rectangular- including square, or any other cross-sectional shape which cannot be described as circular (defined by a constant radius rotated about a point). The non-round shapes may have one or two axes of symmetry or may have no axis of symmetry in their cross-sections taken normal to a longitudinal axis of the wire. For any of the non-round shapes. However, there is a reference axis which ideally is oriented in a particular orientation relative to the workpiece during a welding operation.

[0026] Referring first to Figure 1 , a welding torch 10 is shown as an example of a welding system which may incorporate the end assembly 30 in accordance with the present invention. Torch 10 incorporates end assembly 30, having nozzle 22, gooseneck 24, tip 26 and diffuser 28. A flexible coiled wire guide 12 is shown for conducting consumable electrode wire 14. The welding torch 10 shown in Figure 1 can be for use in gas metal arc welding (GMAW) also known as metal inert gas (MIG) welding or metal active gas (MAG) welding and any other types of welding well known in the art. Torch 10 is shown as a handheld device for welding applications. However, many welding systems incorporate robot controlled or guided welding torches, which would have a different configuration than that illustrated using design approaches well known in the prior art.Attorney Docket No.: 91694-171However, end assembly 30 in accordance with the present invention has applications for such robot controlled or other machine guided welding systems.

[0027] In one embodiment, welding torch 10 receives a continuous feed, consumable wire electrode 14. The wire electrode or weld wire 14 extends through the central or axial bore 16 of the contact tip 26. Weld wire 14 is axially fed through the contact tip 26 by a conventional wire feeder (not shown). Weld wire 14 contacts and slides against the inner wall of the contact tip 26 during the passage of the weld wire through the contact tip which establishes an electrical conductivity path necessary for transfer of electrical current to the weld wire. In other applications, such as laser welding, electrical contact may not be needed with weld wire 14.

[0028] The bore 16 of the contact tip 26 is sized to receive weld wire 14 and to maintain continuous contact between the contact tip 26 and the weld wire while allowing the weld wire 20 to freely pass through the contact tip. In typical embodiments, the size and shape of the bore 16 corresponds to weld wire 14 such that the standard clearances are provided.

[0029] As mentioned previously, a principal feature of the present invention is the ability to orient the cross-sectional axes of consumable electrode wire 14 in a precise manner relative to a workpiece and the direction of weld progression. Examples are provided with reference to Figures 2A, 2B and 2C. Contact tip 26 has bore 16 which can be formed with a variety of cross-sectional shapes to accommodate the configuration of non-round electrode wire 14 being used. The nonround shape enables weld wire 14 to be orientated to accommodate different types of welding needs and to produce different types of weld sizes and weld penetrations as illustrated by Figures 2B and 2C. Figure 2A provides an example of a welding process using conventional prior art round weld wire. For weld wire 14 having a non-round cross-sectional shape, the plasma stream 18 created during welding has a similar elliptical shape. The ability to orientate weld wire 14 allows for better control over the depth of penetration A2 or A3 of the weld 20, as shown by Figures 2B and 2C.

[0030] When the weld wire 14 is orientated so that the minor axis B2-B2 is essentially aligned with the welding direction (which is into and out of the page as the figures are illustrated), the weld wire 14 having the non-round cross-sectional shape provides a smoother weld bead to weldAttorney Docket No.: 91694-171 material transition than with a weld created using a weld wire with a circular cross-sectional shape as shown in Figure 2A. When weld wire 14 is positioned such that the minor axis B2-B2 is essentially aligned in the weld direction as shown by Figure 2B, the plasma stream 18 is broader than as shown in Figure 2A which provides weld 20 having a broader bead margin than with a weld created using a weld wire with a circular cross-sectional shape with depth penetration K2 which is less than the depth penetration A1 for a weld created using a weld wire having a circular cross-sectional shape.

[0031] When the weld wire 14 is positioned such that the major axis A2-A2 is essentially aligned in the welding direction as shown by Figure 2C, the plasma stream 18 is narrower, which provides a weld 20 having a narrower bead margin than with a weld created using a weld wire with a circular cross-sectional shape as shown in Figure 2A while achieving a depth penetration A3 which is greater than a depth penetration A1 of a weld created using a weld wire having a circular cross-sectional shape. The ability to orient weld wire 14 also allows for better control over the size and nature of the heat affected zone (HAZ) of the weld site which allows the thickness or dimension of the HAZ to be better controlled. End assembly 30 in accordance with the present invention allows a precise orientation of the major and minor axes (A2-A2, B2-B2) of the nonround wire 14 relative to the desired weld 20 by establishing the orientation of tip 26 relative to torch 10.

[0032] Now referring to Figures 3-7, details of end assembly 30 are described. Principal components of end assembly are; nozzle 22, gooseneck 24, contact tip 26, diffuser 28, nut 31 , sleeve 32 and adapter 34. These components are shown assembled in Figures 3 and 4.

[0033] Gooseneck 24 is of generally conventional construction, formed of a tube having external threads 35 and internal threads 36. Gooseneck 24 includes conventional components such as wire guide 12 components (shown in Figure 1) fortransporting consumable wire electrode 14 through the gooseneck and also provides a pathway for the flow of welding shielding gas.

[0034] Adapter 34 forms a sleeve with internal threads 36, external threads 39 and further forms a narrowed central bore 38. Adapter 34 is threaded into the inside of gooseneck 24, meshing threads 36 and 39.Attorney Docket No.: 91694-171

[0035] As best shown in Figure 4, diffuser 28 includes external threads 40, which are threaded into and mesh with adapter internal threads 37 to mount the diffuserto adapter 34 in an assembled condition.

[0036] One open end 41 of diffuser 28 forms open internal cavity 42 with an entry section forming internal threads 43 adapted for meshing with an end piece for wire guide 12 (not shown) and a narrowed section forming a number of a cross drilled bores 45 for conducting shielding gas. The opposite open end 44 of diffuser 28 exposes an internal cavity having a number of features. Internal surface 47 interacts with features of tip 26 which will be described further below. Central bore 48 provides a pathway for a consumable electrode wire 14. Internal surface 47 terminates in a concave surface 50 centered at central bore 48. Concave surface 50 preferably is shaped as a surface defined by a curved line rotated about the longitudinal centerline of diffuser 28. Surface 50 provides an interaction with a surface of tip 26 consistent with applicants “Powerballtm” connection, which provide an excellent pathway for the conduction of electric current and heat transfer for maintaining cooling of tip 26.

[0037] Contact tip 26 features a rounded distal end 52 and a proximal end 54, featuring a convex surface 58 which closely matches and mates with diffuser concave surface 50, again to provide the “Powerballtm” interaction mentioned previously. Contact tip 26 forms shoulder 56 and an external surface 59 having protrusions or other features, such as hexagonal surfaces, splines or other features which mesh with diffuser surface 47. The interaction of surfaces 47 and 59 provide a fixing of the angular orientation of tip 26 relative to diffuser 28 relative to bore 48 and the axis of electrode wire 14. Depending on the shape of the features of the surfaces, a number of discrete angular indexed orientations can be provided. If a high degree of angular position setting is necessary, these features may be small and numerous. For example, if a hexagonal surface interaction is chosen, then six different discrete angular orientations can be provided, each 60° apart. By the use of splines for example, or flattened surfaces greater in number than six, a higher number of discrete positions may be provided. In another arrangement, the indexed orientation provides only one meshing inserted position of tip 26 within diffuser 28, such as provided by a key or flattened surface interaction between tip 26 and diffuser 28. This establishesAttorney Docket No.: 91694-171 one desired angular indexed orientation of tip 26, which will position the major and minor axes A2-A3 and B2-B3 of wire 14 in a desired orientation relative to the intended welding operation.

[0038] Tip 26 internal bore 60 terminates at distal end 52 with a tip opening 61 which closely conforms to the outer surface dimensions and shape of the non-round electrode wire 14 being used. It is important that opening 61 closely conforms to the cross-sectional shape of wire 14 to provide the necessary electrical conduction pathway between them to enable the welding operation (when used with electrical resistance welding systems). Moreover, this close confirmation establishes the orientation of the wire 28 relative to end assembly 30, and the intended welding operation, a principal feature of the present invention.

[0039] Tip 26 is maintained in a mounted condition within diffuser 28 using nut 31. Preferably, nut 31 forms internal Acme or buttress type threads which interact with diffuser threads 62 to provide a high degree of clamping force urging the “Powerball™” surfaces 50 and 58 to interact. Moreover, depending on the configuration of surfaces 47 and 59, nut 30 enables tip 26 to the placed into diffuser 28 in one or a number of angular orientations as desired for establishing the desired orientation of the cross-section of wire 28.

[0040] Nozzle 22 forms internal threads 66 which mesh with external threads 68 of sleeve 32. Sleeve 32 further forms internal threads 70 which mesh with external threads 35 of gooseneck 24. Figure 4 illustrates the assembled condition of all of the elements. In a welding operation using torch 10, shielding gas conducted by gooseneck 24 flows into cavity 42 and escapes through cross drilled bores 45. From there, the gas flows through the annular space provided around diffuser 28 and nozzle 22, and finally to the distal end of the nozzle where it is oriented to provide shielding gas for the weld puddle formed during a welding operation.

[0041] Now with reference to Figures 8A-8F, additional embodiments of end assembly 30 in accordance with the present invention are illustrated, each providing the precise indexing features described previously.

[0042] Figure 8A illustrates end assembly 30A having features consistent with the prior embodiment described above but providing a different indexing feature. In this case external surface 59A of tip 26A is in the form of splines and internal surface 47A of diffuser 28A is formedAttorney Docket No.: 91694-171 to have internal splines which mesh with surface 59A. This configuration provides a greater number of discrete angular positions can be set between tip 26A and diffuser 28A as the tip is placed into an assembled condition with the diffuser and nut 31 is tightened. The number of discrete angular positions is determined by the angular separation of individual splines formed by surfaces 47A and 59A.

[0043] Figure 8B illustrates end assembly 30B having features consistent with the prior described first embodiment but providing a different indexing feature. In this case external surface 59B of tip 26B is in the form of a hexagonal surface and internal surface 47B of diffuser 28B is formed to have a single flattened region or inward directed protrusion which meshes with the one of the flats of hexagonal surface 59B. This configuration provides six discrete angular positions between tip 26B and diffuser 28B as the tip is placed into an assembled condition with the diffuser and nut 31 is tightened. Different polygonal shapes can be provided for surface 59B, depending on the number of discrete positions desired. Moreover, external surface 59B could be provided, having only a single flattened surface. This configuration enables one discrete angular position to be set, a configuration which may be desired in some applications.

[0044] Figure 8C illustrates end assembly 30C having features consistent with the first described embodiment but providing a different indexing feature. In this case external surface 59C, of tip 26C is a smooth tapered shoulder and internal surface 47C of diffuser 28C is also formed to have a smooth taper or conical shoulder, which mates with surface 59C. This configuration provides an infinite number of discrete angular positions between tip 26C and diffuser 28C as the tip is placed into an assembled condition with the diffuser and nut 31 is tightened.

[0045] This configuration of end assembly 30C like other embodiments described herein could incorporate indexing marks on tip 26C and diffuser 28C to provide accurate setting of the angular orientation desired. For example, simple indexing marks 70 and 72 are illustrated in Figure 8C, which are keyed to the angular orientation of tip opening 61 and, when using a generally elliptical tip opening shape, the orientation of its major and minor axes A2-A2, and B2- B2. Such indexing marks 70 and 72 could be provided for any of the alternate embodimentsAttorney Docket No.: 91694-171 described herein. Moreover, the indexing marks 70 and 72 could be embodied as an angular scale running around the perimeter of one the surfaces of tip 26C and diffuser 28C. Indexing marks 70 and 72 would likely be rendered unusable after use of end assembly 30, and any of the other described embodiments after use due to weld splatter. Indexing marks 70 and 72 could be replaced by more prominent features such as notches, protrusions, indentations, etc. indicating angular orientation which may be more survivable in the intended operating environment.

[0046] Figure 8D illustrates end assembly 30D having features consistent with the first described embodiment but providing a different indexing feature. In this case external surface 59D of tip 26D is in the form of a hexagonal surface and internal surface 47D of diffuser 28D is formed to have a complementary internal hexagonal surface which mesh with surface 59D. This configuration provides a six discrete angular positions between tip 26D and diffuser 28D as the tip is placed into an assembled condition with the diffuser and nut 31 (or other fastener) is tightened.

[0047] Figure 8E illustrates end assembly 30E having features consistent with the first described embodiment but providing a further different indexing feature. In this case, external surface 59E of tip 26E is in the form of downward opening scallops which could be described as an inversed castellated surface. Diffuser 28E, features and internal projecting pin 76, or other inward protrusion which meshes with one of the scallops of tip 26E when the parts are assembled. This configuration provides a number of discrete angular positions between tip 26E and diffuser 28E equal to the angular separation of individual downward projecting scallops as the tip 26E is placed into an assembled condition with the diffuser 28E and nut 31 is tightened.

[0048] While the above-described indexing arrangement allows for the precise control of the orientation of the non-round wire as it exits the end assembly, it is also desirable to maintain, control and / or guide the non-round wire as it is entering the gooseneck 24 of the end assembly 30.

[0049] Figures 9-1 1 illustrate a system 100 for guiding the non-round wire into the gooseneck 24, which allows the gooseneck 24 and its holder to rotate relative to the wire guide 12 while maintaining the wire in a desired orientation.Attorney Docket No.: 91694-171

[0050] Figure 9 shows the system 100, and illustrates the gooseneck 24 with elements of the end assembly 30 removed for clarity. As shown, gooseneck end piece 102 projects outward from the end of the gooseneck 24. End piece 102 has a Powerball end 104 having a radiused or curved outer surface configured to mate with a corresponding radiused and curved concave recess (Powerball) inside of the diffuser 28. Each of the various indexing assemblies can therefore be attached to the to the end piece 102 by attaching the corresponding diffuser 28 to the end piece 102 via the threaded connection.

[0051] The gooseneck 24 is attached to holder 106. The holder 106 is configured for attached to the wire guide 12 (also referred to as a cable or torch cable). The holder 106 includes a gooseneck end portion 106a, a central body portion 106b, and a cable end portion 106c. The cable end portion 106c is configured for attachment to the cable 12, and can be configured to rotate relative to the cable 12 via the connection therebetween. In a welding system where current is provided, current passes from the cable 12 and is transferred via the rotatable connection into the holder 106, which passes the current to the gooseneck 24 attached to the opposite end and ultimately to the contact tip. The cable 12 also provides the shielding gas (when used), and of course the non-round wire.

[0052] As shown in Figures 10 and 1 1 , cable end portion 106c of the holder includes a conductive block 108, through which current will pass. The conductive block can be made of copper or the like. The conductive block 108 may include a central passageway, in which an inlet guide 110 is provided. The inlet guide 110 delivers the non-round wire from the cable 12 into the central portion 106b.

[0053] The central portion 106b includes a plurality of guide rollers 1 12 configured to orient and guide the non-round wire. In one aspect, the guide rollers 1 12 are oval-shaped, having a concave outer surface arranged to correspond to the wide side of the non-round wire. The rollers 1 12 may be held via plain bearings, posts, or other similar structure to allow for generally free rotation of the rollers 112 as the wire is guided therethrough.

[0054] In one aspect, four rollers 112 are provided, with two rollers being above the wire and two rollers being below the wire. The rollers 1 12 may each be longitudinally offset relative to eachAttorney Docket No.: 91694-171 other, but still axially aligned, so that the wire is supported on the top and bottom at different longitudinal locations. The rollers 112 may be offset in a staggered alternating arrangement as shown, or may be arranged in a non-alternating arrangement, in some instances. The number of rollers may also be adjusted depending on the needs of the user.

[0055] The rollers 112 may be fixed in place via mounting to the bearing pins, which may in turn be attached to a mounting block 114 disposed within the central portion 106b. The mounting block may be integral with the body of the central portion 106b, or may be separately attached. The rollers 112 may therefore be positing in line with the inlet guide 110 such that the wire exiting the inlet guide 110 is fed directly into the central axis defined by the surfaces of the rollers.

[0056] The gooseneck end portion 106a of the holder may also include a conductive block 116, into which the wire is fed from the central portion 106b. The conductive block 116 is conductively connected to the end piece 102, which ultimately passes current to the contact tip of the end assembly 30.

[0057] The conductive block 116 may further include a gas fitting 118, which can be connected to a supply of shielding gas (when used). The gas fitting 118 routes the shielding gas into the front of the gooseneck for delivery via the nozzle of the end assembly 30.

[0058] The central portion 116b may include an opening / window 120, though which the shielding gas tube can be routed and attached to the gas fitting 118. This opening 120 also provides a view of the functioning of the rollers 112

[0059] In another approach, the shielding gas may be provided through an outlet or fitting disposed in the block 108 of the cable end portion 106c, with the gas fitting 118 fluidically connected thereto. The window 120 may still be provided to allow maintenance of the central portion 106b.

[0060] Similar to the provision of shielding gas, in a conductive welding process, the current must still be passed from the cable end 106c to the gooseneck end 106a so that the current can reach the end of the end assembly 30. Accordingly, each of the blocks 108 and 116 may include recesses 122 formed therein (along with set screws interacting with the recesses) configured to receive and retain power jumpers 124 extending therebetween. The power jumpers 124 areAttorney Docket No.: 91694-171 conductive and operable to pass the current from the cable end portion 106c to the gooseneck end portion 106a.

[0061] The power jumpers 124 and the gas fitting 118 are provided in the central portion 106b to allow for gas shielded arc welding type processes. However, the non-round wire may also be used in laser welding or other radiant heat type welding processes, in which shielding gas and current may not be necessary. Accordingly, in such processes, the central portion 106b may excluded these elements, while still providing the benefits of the controlled and guided orientation of the non-round wire through the holder 106.

[0062] Thus, as the non-round wire is fed through the system and the cable 12, and even as the holder 106 and end assembly 30 may move during the welding process, the rollers 112 will keep the wire from twisting and / or binding as it is provided into the gooseneck 24. Thus, the end assembly 30 may be provided with additional range of movement.

[0063] The above guide rollers 112 and holder 106 may be used in various welding systems and end assemblies 30, and are not limited to use with the various indexed nozzle and contact tip arrangements described above. For instance, other nozzle and contact tip arrangements allowing for non-round wire to be delivered may also be used, even including nozzles and contact tips with circular openings. The rollers 112 in that case can thereby be used to orient the wire as it is being fed into the gooseneck, for instance.

[0064] While the above description constitutes the preferred embodiments of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.

Claims

Attorney Docket No.: 91694-171CLAIMSWhat is claimed is:

1. A holder for use with an end assembly for a welding device for use with a consumable electrode having a non-round cross-sectional shape and defining at least one reference cross- sectional axis, comprising: a holder assembly including a cable end portion, a central portion, and a gooseneck end portion; wherein the cable end portion is configured to attachment to a wire guide cable that provides the consumable electrode into the holder; wherein the gooseneck end portion is configured for attachment to a gooseneck of an end assembly for welding system; wherein the central portion is disposed between and connects the cable end portion and the gooseneck end portion; a plurality of rollers disposed within the central portion; wherein the rollers have an outer surface corresponding to an outer surface of a nonround wire; wherein the rollers are configured to orient and maintain the reference cross-sectional axis of the non-round wire as the non-round is fed through the holder.

2. The holder of claim 1 , wherein the rollers have a concave outer surface configured to correspond to an oval shape of the non-round wire.

3. The holder of claim 1 , wherein the plurality of rollers includes four rollers.

4. The holder of claim 1 , wherein at least one of the rollers is disposed above the non-round wire and at least one of the rollers is disposed below the non-round wire.Attorney Docket No.: 91694-1715. The holder of claim 1 , wherein two rollers are disposed above the wire and the two rollers are disposed below the wire.

6. The holder of claim 5, wherein the rollers are staggered longitudinally along the non-round wire.

7. The holder of claim 1 , wherein the cable end portion includes a conductive block and the gooseneck end portion includes a conductive block, wherein the rollers are disposed between the conductive blocks.

8. The holder of claim 7, wherein the conductive blocks each include a recess, wherein a conductive power jumper extends between the blocks and into each of the recesses, wherein the conductive power jumper transfers current between the blocks to thereby transfer current from the cable end portion to the gooseneck end portion.

9. The holder of claim 1 , wherein the rollers are free rolling and mounted on corresponding posts within the central portion.

10. The holder of claim 9, wherein the rollers are removable retained on the pins to allow for replacement by other rollers.11 . The holder of claim 7, wherein the block of the gooseneck end includes a gas fitting that receives shielding gas for delivery to an attached end assembly.

12. The holder of claim 1 , wherein the holder is configured to be rotatable relative to the wire guide cable.Attorney Docket No.: 91694-17113. The holder of claim 1 , wherein the holder is attached to an end assembly having a gooseneck, diffuser, contact tip, and nozzle, wherein the holder provides the non-round wire to the end assembly.

14. The holder of claim 1 , wherein the holder is attached to a wire guide cable, wherein the holder receives the non-round wire from the wire guide cable.

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