UNDERWAT

ER
WELDING
Presented by:
• Manav Patel (23BME050)
• Manav Shah (23BME051)
• Param Mankad (23BME052)
• Mazin Vora (23BME053)
• Dhruval Meniya (23BME054)
• Aditya Modi (23BME055)
• Vashistha Modi (23BME056)
• Laraib Saiyad (23BME057)
• Kartavya Mori (23BME058)
Table of Contents
0
1
Introduct
ion
INTRODUCTION
Underwater Welding: Underwater welding is a specialized process of
joining metal structures while submerged in water. It combines traditional welding
techniques with commercial diving skills to repair, maintain, or construct
underwater structures such as ships, oil rigs, and pipelines.

Essential for repairing and maintaining ships, oil rigs, pipelines, bridges, and
dams without needing to remove them from the water.

Types of underwater welding are as followed:

Wet Welding: Performed directly in the water using waterproof electrodes.

Dry (Hyperbaric) Welding: Conducted in a dry, pressurized chamber

underwater.
HISTORY
● The invention of arc welding in the early 1900s made underwater welding
more practical.
● The first known use of underwater welding dates back to 1800s, when rivet
repair techniques were used for ship maintenance.
● The first true underwater welding was developed in the 1930s by
Konstantin Khrenov, a Soviet engineer.
● During World War II, underwater welding became essential for repairing war-
damaged ships and structures.
● Development of wet welding techniques using waterproof electrodes.
Growth of the offshore oil and gas industry increased the demand for
underwater welding.
● Hyperbaric (dry) welding became more common for deeper and more
precise welding. Advances in diving technology, robotics, and automation
have improved safety and efficiency.
2
Types of
Underwater
Welding
Types of Underwater Welding
Wet Welding: Wet welding is a process where the welder
performs welding directly underwater without isolating the work
area from the surrounding water.

● Uses waterproof-coated electrodes that generate a

protective gas shield (bubbles) around the molten weld pool.
● The electric arc creates intense heat (~3,000-5,000°C),
melting the base metal and forming the weld.
● The rapid cooling of the weld due to water exposure increases
the risk of defects like hydrogen embrittlement.
Types of
Underwater
Welding
A. Shielded Metal Arc Welding (SMAW) –
Most Common Method:
✔Uses waterproof stick electrodes with
flux coating to shield the weld.
✔ The arc is created between the
electrode and workpiece, melting both
to form a weld.
✔ Common for ship repairs, offshore
structures, and emergency fixes.
B. Flux-Cored Arc Welding (FCAW):
✔ Uses a hollow electrode filled with flux
to create a protective gas bubble.
✔ Less common than SMAW but
provides better weld quality.
✔ Used for underwater construction and
pipeline repair.
Types of Underwater Welding
Dry welding: involves creating a sealed, dry environment
around the welding area using a hyperbaric chamber. This method
ensures a high-quality, contamination-free weld and is used for
deep-sea applications.

• A chamber is placed around the workpiece to create a dry,

controlled atmosphere.
• The chamber is pressurized to prevent water from entering.
• Welding is performed using traditional methods like TIG, MIG, or
Stick welding.
• Since there is no water interference, the weld quality is superior
to wet welding.
Types of
Underwater
Welding
A. Dry Chamber Welding
✔ A small, localized chamber is placed
over the weld area.
✔ The diver inserts hands inside gloves
attached to the chamber to weld.
✔ Used for shallow-depth repairs where
full chambers are impractical.
B. Dry Habitat Welding
✔ A large chamber is built around the
work area, allowing divers to move
freely.
✔ Used in deep-sea construction,
offshore oil rigs, and pipeline welding.
✔ More complex but provides the best
weld quality.
Comparison: Wet Welding vs.
Dry
Feature
WeldingWet Welding (Direct in Water) Dry Welding (Hyperbaric
Chamber)
Lower (Hydrogen
Weld Quality Higher (Clean, strong welds)
embrittlement, porosity)
High (Chamber, gas supply
Cost Low (No extra setup)
needed)
Slow (Chamber installation
Setup Time Fast (Minimal equipment)
required)
Depth Limit Shallow (Up to 100m) Can go deeper
Safety More electrical hazards Safer, controlled environment
Best Use Emergency ship repairs Offshore deep-sea welding
3
Equipments
 Equipment’s Required
1. Power 2. Welding 3. Diver’s
Supply Equipme Equipme
System nt nt
• Direct Current (DC) • Waterproof Coated • Surface-Supplied
Power Source – Used Electrodes – Diving Suit –
instead of AC to prevent Designed to Provides breathing
electric shock hazards. withstand water gas from the
• Control Unit – Regulates exposure and surface.
voltage and current for create a protective • Depth Gauge &
stable arc performance. gas shield. Pressure Sensors,
• Grounding Cable & • E6013 (general- Rubber-Insulated
Clamps – Ensures a safe purpose wet Gloves, Protective
electrical path. welding) face shield
• E7014 (high-
strength
applications)
• Welding Torch or
4
Working
Principle
Working Principle
The most commonly used wet welding technique is
SMAW and FCAW.

The primary goal is to create a strong metallic bond

between two workpieces using heat generated by an
electric arc. However, welding in water introduces
several challenges, such as water’s electrical
conductivity, rapid heat dissipation, and limited
visibility.

The welding process begins by striking an electric

arc between the welding electrode and the metal
workpiece. This arc generates extremely high
temperatures (around 3,000–5,000°C) that melt
the base metal and electrode, forming a molten
weld pool.

The electrode is coated with a waterproof flux

that releases protective gases (such as carbon
dioxide or hydrogen) when heated. However, some
water still mixes with the weld, which can lead to
hydrogen embrittlement (making the weld brittle).
5
Effect on
Weld
Effect Of Underwater Welding
1. Effects on Weld Quality:
A. Hydrogen Embrittlement
• Cause: Water contains hydrogen, which gets absorbed into the molten weld
metal.
• Effect: Weakens the weld, making it brittle and prone to cracking.
• Solution: Use of special coated electrodes and dry welding techniques.
B. Porosity & Weld Defects
• Cause: Rapid cooling and trapped gases cause tiny holes (porosity) in the
weld.
• Effect: Reduces weld strength and durability.
• Solution: Proper electrode selection and controlled welding techniques.
C. Thermal Stresses
• Cause: Water cools the weld too quickly.
• Effect: Increases the risk of cracks, hard spots, and stress fractures.
• Solution: Using dry welding methods or preheating techniques.
Effect Of Underwater Welding
2. Equipment and safety risks.
A. Corrosion & Rusting
• Cause: Exposure to saltwater speeds up metal oxidation.
• Effect: Reduces the lifespan of electrodes, cables, and welding tools.
• Solution: Regular maintenance and use of corrosion-resistant materials.
B. Electrical Hazards
• Cause: Water conducts electricity, increasing the risk of short circuits.
• Effect: Can cause equipment failure and serious safety risks.
• Solution: DC power sources, insulated cables, and proper grounding.
C. Electric Shock Risk
• Cause: Water conducts electricity, increasing the chance of electrical
accidents.
• Effect: Severe injury or even death.
• Solution: Use proper insulation and protective gear.
Effect Of Underwater Welding
3. Effects on the Environment:
A. Marine Pollution
• Cause: Welding generates metal oxides and electrode coatings that dissolve in
water.
• Effect: Harms marine life and water quality.
• Solution: Use eco-friendly welding materials and proper disposal methods.
B. Disturbance to Marine Life
• Cause: Bright welding arcs, noise, and vibrations disrupt sea creatures.
• Effect: Alters fish migration and breeding patterns.
• Solution: Regulating welding times and using shielding techniques.
C. Preventing Oil & Gas Leaks
• Positive Effect: Welding is essential for maintaining underwater pipelines and
oil rigs.
• Negative Effect: If done improperly, it can cause oil spills.
• Solution: Follow strict safety standards and quality control.
6
Challenges &
Risks
Challenges
Risks
7
Safety Measure
& Precaution
Safety Measures
Precaution
8
Application
Applications
9
Conclusion
Conclusion
Summary of the complete presentation
Citation
● https://www.sciencedirect.com/topics/engineering/underwater-welding
Thank You!
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