Submerged arc welding systems and submerged arc welding torches to resistively preheat electrode wire

A submerged arc welding torch, comprising:

• a first contact tip and a second contact tip configured to conduct preheating current through a portion of an electrode wire being fed through the torch;
• an air-cooled first conductive body portion configured to conduct the preheating current to the second contact tip via a first power connector;
• an air-cooled second conductive body portion configured to receive the preheating current via a second power connector and to conduct the preheating current to the first contact tip;
• an insulator mechanically coupling the first conductive body portion to the second conductive body portion and electrically insulating the first conductive body portion from the second conductive body portion, wherein the insulator is configured to guide the electrode wire from the first conductive body portion to the second conductive body portion;
• and
• a wire guide extending through the first conductive body portion, the insulator, and the second conductive body portion.

A submerged arc welding system, comprising:

• a submerged arc welding torch, comprising:
• a first contact tip configured to transfer weld current and preheating current to the electrode wire;
• a second contact tip configured to conduct the preheating current to the electrode wire;
• an air-cooled first conductive body portion configured to receive the weld current at a first power connector and to conduct the weld current and the preheating current to the first contact tip;
• an air-cooled second conductive body portion configured to receive the preheating current at a second power connector and to conduct the preheating current to the second contact tip;
• and
• an insulator configured to detachably connect the first conductive body portion to the second conductive body portion and to electrically insulate the first conductive body portion from the second conductive body portion while connected;
• and
• one or more power supplies configured to output the weld current and the preheating current to the submerged arc welding torch.