Dual twin-saw wire cladding

A system for cladding a workpiece, the system comprising:

• a first twin submerged arc welding (“SAW”) head arranged proximal to a second twin SAW head, the first twin SAW head configured to:
• direct at least two first consumable wires toward a surface of the workpiece;
• and
• introduce a first current to the at least two first consumable wires for melting the at least two first consumable wires via resistive heating when they contact a molten slag pool formed on the workpiece;
• and
• the second twin SAW head configured to:
• direct at least two second consumable wires toward the surface of the workpiece;
• and
• introduce a second current to the at least two second consumable wires for melting the at least two second consumable wires via resistive heating when they contact the molten slag pool formed on the workpiece;
• and
• a flux hopper configured to apply a conductive electroslag flux to the surface of the workpiece, wherein the conductive electroslag flux facilitates resistive heating of the at least two first consumable wires and the at least two second consumable wires to melt the conductive electroslag flux without generating an arc and form the molten slag pool, and the conductive electroslag flux electrically couples the at least two first consumable wires to one another to facilitate heat transfer to encourage formation of a thick cladded deposit on the workpiece via the molten slag pool;
• wherein the first and second twin SAW heads are configured to translate together to form the thick cladded deposit across the surface of the workpiece.