Abstract: A hot wire welding method and system includes a welding torch with a non-melting electrode, a melting metal filler wire fed into the weld puddle created by the welding arc, a microprocessor controller for controlling the current of the main welding arc, filler wire feed speed, and hot wire current control for the heating of the hot wire. The method and system also includes a main welding power supply for supplying the main welding arc and a secondary DC supply for supplying the hot wire current. The hot wire current is automatically controlled by the microprocessor to supply the correct amount of hot wire current to the filler wire with changes in wire feed speed.