Abstract: In response to the problems of large heating area of the workpiece base material, large welding deformation, large post welding grinding amount, and multiple welding repair parts in the manufacturing of rectangular box components of a certain type of engineering machinery product, research and testing of high current metal powder core welding wire technology were carried out. By comparing and analyzing the welding performance quality, spatter, wire feeding speed and process parameters, welding and grinding material costs, and other aspects with the current solid core welding wire, and evaluating the comprehensive application factors, a more suitable welding process method for long straight welds of rectangular box components is found.