Single-Pass Process of Square Butt Joints without Edge Preparation Using Hot-Wire Gas Metal Arc Welding

This paper presents a novel approach to welding thick steel plates that offers time and energy savings compared with conventional techniques. The combination of gas metal arc (GMAW) hot-wire technology simplifies the joint configuration enhances process tolerance. In this study, square butt was prepared as-cut edges thickness 15 mm. relationship between current deposition rate solo GMAW showed limitations low Increasing led larger deposited volume unnecessary weld penetration. An independent due insertion used improve provided an additional without increasing reduced With optimized parameters, full-penetration single-pass achieved. Compared formation typical single-v at similar speed 30 cm/min, proposed minimum power consumption by approximately 83% 62%, respectively. Moreover, single pass travel 60 cm/min achieved 91% 81% less consumption, summary, combined configuration, enables welding, reduces requirements.