Energy input measurements and application of a GMAW hot-wire process with indirect resistive heating of the auxiliary wire

Abstract In view of the current challenges in manufacturing, particularly with regard to the utilisation of resources, there is an urgent need to improve existing arc processes in order to maintain economic efficiency. In this study, a novel GMAW process using a preheated hot-wire (HW) is presented, which has been the subject of scientific investigation for the first time in order to enable its targeted application in industrial environments. Through the investigations carried out, it has been demonstrated that the weld geometry and material input can be adjusted while maintaining constant energy input. This is achieved by varying the hot-wire current and the feed rate. The flexibility of the process, enabled by preheating the wire without contact with the weld pool and advanced control algorithms, allows for a wide range of parameter adjustments. Furthermore, an analysis of cladding has demonstrated that the GMAW hot-wire process (GMAW-HW) with indirect resistive heating of the auxiliary wire has significant potential to enhance productivity in these applications, outperforming conventional GMAW and GMAW-HW processes. This research underscores the promising prospects for industrial implementation and provides a pathway to more efficient and adaptable joining technologies.