| Abstract Scope |
Hybrid laser–arc welding (HLAW) offers significant productivity advantages over conventional arc welding. Still, it is currently limited in joining thick high-strength steels due to penetration constraints and concerns regarding weld hardness and impact toughness. This research investigates a sequential welding approach that combines HLAW and submerged arc welding (SAW) for one-sided joining of 38-mm-thick high-strength steel plates. HLAW is used to produce an approximately 18 mm deep root weld, followed by SAW to complete the joint thickness. The approach aims to reduce groove volume, filler metal consumption, heat input, fabrication time, and distortion while meeting the mechanical performance requirements of demanding structural applications. Process development, welding procedure optimization, and metallurgical and mechanical characterization are presented to evaluate the feasibility of the combined process. The results demonstrate the potential of the sequential HLAW–SAW process to improve productivity while producing high-integrity welds for shipbuilding, heavy manufacturing, and energy applications. |