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<p>To address the challenges of low welding efficiency and difficult deformation control in the fabrication of thick plates for offshore wind turbine towers, this study investigates the Narrow-Gap Twin-Wire Submerged Arc Welding process using 75&#xa0;mm-thick DH36 low-alloy high-strength steel as the base material. A U-shaped groove geometry was designed, and a single-layer double-pass welding procedure was developed. The welding parameters were optimized in conjunction with the implementation of a pre-deformation control strategy. Furthermore, a novel single-layer single-pass welding technique employing a U-shaped narrow groove was proposed. Experimental results demonstrate that the single-layer double-pass welding process produced defect-free welds with satisfactory formation when a 4&#xa0;mm pre-deformation was applied. For the single-layer single-pass welding, appropriate control of the torch offset (≤ 3&#xa0;mm) effectively eliminated sidewall lack of fusion and slag inclusion defects. Numerical simulations conducted using SYSWELD confirmed the temperature field and residual stress distribution characteristics, revealing a dumbbell-shaped residual stress pattern concentrated in the central region and at both ends of the weld. This work provides a practical and theoretical foundation for achieving high-efficiency and high-quality welding of thick plates used in offshore wind tower fabrication, offering valuable guidance for industrial application and process optimization.</p>

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A Study on the Twin-Wire Narrow-Gap Submerged Arc Welding of 75-mm-thick DH36 Steel

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Kaijian Lin,
  • Jianming Tang,
  • Bin Hu,
  • Dong Zhang,
  • Lei Shan,
  • Ruifeng Li,
  • Kai Qi,
  • Fangming Zhou,
  • Taotao Li

摘要

To address the challenges of low welding efficiency and difficult deformation control in the fabrication of thick plates for offshore wind turbine towers, this study investigates the Narrow-Gap Twin-Wire Submerged Arc Welding process using 75 mm-thick DH36 low-alloy high-strength steel as the base material. A U-shaped groove geometry was designed, and a single-layer double-pass welding procedure was developed. The welding parameters were optimized in conjunction with the implementation of a pre-deformation control strategy. Furthermore, a novel single-layer single-pass welding technique employing a U-shaped narrow groove was proposed. Experimental results demonstrate that the single-layer double-pass welding process produced defect-free welds with satisfactory formation when a 4 mm pre-deformation was applied. For the single-layer single-pass welding, appropriate control of the torch offset (≤ 3 mm) effectively eliminated sidewall lack of fusion and slag inclusion defects. Numerical simulations conducted using SYSWELD confirmed the temperature field and residual stress distribution characteristics, revealing a dumbbell-shaped residual stress pattern concentrated in the central region and at both ends of the weld. This work provides a practical and theoretical foundation for achieving high-efficiency and high-quality welding of thick plates used in offshore wind tower fabrication, offering valuable guidance for industrial application and process optimization.