Abstract Multi-wire submerged arc welding (SAW) techniques offer potential advantages for welding structural steels, but their effects on weld geometry, heat input, microstructure, and local hardness must be carefully evaluated. This study investigates the applicability of advanced submerged arc welding (SAW) techniques employing multiple wires configurations, namely tandem arc and twin arc with cold wire addition. The twin-ICE (Integrated Cold Electrode) technique, involving cold wire feeding, has recently gained attention for its potential to reduce the effective heat input and enhance the mechanical properties and structural integrity of welded joints. Nine specimens were fabricated: three using the tandem arc process and six using the twin-ICE configuration, varying the cold wire feeding ratio. The joints were evaluated through optical and scanning electron microscopy, stereoscopy, and microhardness mapping. Preliminary results indicate that cold wire addition may reduce the effective heat input, leading to a narrower HAZ, grain refinement, and a greater qualitative presence of acicular ferrite, consistent with the observed hardness response. While penetration depth may decrease with high cold wire ratios, optimized configurations achieve complete joint penetration (CJP) and improved bead geometry. The findings suggest that both SAW tandem and SAW twin-ICE processes are viable for welding HSLA steel plates up to 16 mm thick within industrially acceptable speed and energy ranges.
Silva et al. (2026) studied this question.