Submerged arc welding (SAW) is a well-established welding process renowned for its capability to join large and thick workpieces, offering high deposition rates. Recently, ESAB has innovated a novel technique that amplifies the deposition rate by utilizing multiple wires while maintaining constant arc energy. There has been limited research employing this configuration, and this dissertation aims to explore the potential applications of this advanced SAW methodology for cladding conventional low-carbon steel (S355JR) with higher alloyed materials, such as 316L stainless steel.

Two distinct buffer fillers were used (309L and 2209) with various cooling conditions and welding parameters to assess their influence on the cladding quality. Visual inspection of the claddings was conducted. Cross-sections were excised to evaluate the dilution, and the presence of eventual imperfections, and to measure the magnetic response in terms of FN of the resulting microstructure.

This investigation will show that high deposition rates in the range of 20 Kg/h can be achieved with low dilution values around 30%, resulting in 5-10 FN (ferrite number) content, which is the optimum microstructure for stainless steel clads.

The conclusion is that a multiwire SAW welding setup with the right welding parameters and conditions can significantly contribute to desirable productivity while at the same time producing high-quality welds with no defects and scarce imperfections.The prospective utility of this enhanced SAW process extends beyond cladding; it harbours potential applications in the additive manufacturing of sizable workpieces. Such an advancement could significantly contribute to sustainability and efficiency in manufacturing or repairing large-scale components, potentially reducing energy consumption and enhancing overall productivity.