CONTENTS

Abstract.3 Introduction....4 Under water welding..5 Working principle...7 Arrangements for under water welding...8 Types of underwater welding......11 Wet welding......12 Principle of operation of wet welding..13 Wet welding process...14 Arrangements for wet welding...15 Disadvantages of wet welding.16 Dry welding..17 Types of dry welding...18 Hyperbaric method..19 Hyperbaric chamber20 Local dry or cavity method.21 Limitation of dry welding...22 Development in UWW...23 Risks involved..24 Scope for further developments...25 Application..26 Conclusion.....27

References..28

ABSTRACT
As the name implies it is the welding done under
water. It is possible to weld under water with an approximate strength of 80% and ductility of 40% of similar welds made in air. There are three methods are employed in under water welding they are wet welding, dry welding, wet-dry welding. Of these in wet welding welder and weld materials are in surrounding water. Welding arc struck on the work piece through a bubble formed by the high temperature between them. In dry welding both welder and diver are in high pressure chamber. In wet-dry welding welder is in surrounding water but the welding material and welding chamber are covered by a small chamber called shroud. Generally used welding process for UVW are shielded metal arc welding(SMAW), gas tungsten arc welding(GTAW),gas metal arc welding (GMAW) and flux cored arc welding(FCAW). Now days it has got wide application in off-shore exploration, drilling and recovery of oil and gases under water constructions etc.

INTRODUCTION
Under water welding was first done by British navy, during First World War, to make temporary repairs on battleships. Normally Shielded Metal Arc Welding (SMA) and Tungsten Inert Gas (TIG) welding arc employed for under water welding process.

UNDER WATER WELDING

Under water welding refers to the welding processes that are performed under water. Used for repairing under water pipelines.

Working principle
Arc welding is high efficiency joining method that uses local melting and solidification by high energy density arc. Power supply is given to both the work and electrode. Electrode is kept in contact with work. Arc is established between the work and electrode when they are separated by a small gap.

ARRANGEMENT OF UNDER WATER WELDING

THE ARRANGEMENTS FOR UNDER WATER WELDING IS SHOWN

For under water welding, DC machine is used as it is safer to use the AC. The voltage requirements for satisfactory welding are lower than for AC and if it is used, then it is difficult to maintain the arc under water. There for DC equipment is readily mounted on the board ship. Negative polarity is preferred. This means that 65-75% of the heat is in the metal being welded. The weld pool is easier to handle and has enough fluidity to fill in undercut to a large extent. When DC is used with positive polarity electrolysis will take place and case rapid deterioration of any metallic components in the electrode holder. Current settings for under water welding are commonly lighter than for welding in air. The power source should be rated at 300-400amps. Motor generated machines are most often used for wet welding. The welding machine frame is grounded to the ship. The welding circuit includes a positive type switch. Usually a knife operated type on the surface and operates by the operator when the welder commands through telephone. The switch in the circuit must be capable of breaking the full current and is used for safely reason. The welding power should be connected to the electrode holder only during welding. Special welding electrode holders with extra insulation against the water are used. Electrode holder utilizes a twist type head for gripping the electrode. It accommodates two sizes of electrodes.

Electrodes with special insulation are used for under water welding. A commonly used electrode type is AWSE6013 classification (American welding Society). For become water proofing special coated with a layer of cellulose nitrate, wax or warmish. It also done by wrapping the electrodes with a water proof type or by dipping it in special sodium silicate mixer and allows them to dry. During welding time these coatings are easily dissolved. Commercial electrodes are available. An essential requirement for under water welding is the complete insulation of the welding circuit so that the electrode cannot come in contact with the water. If the insulation does leak sea water comes in contact with the metal conductor and part of the conductor current will leak away and will not be available at the arc. In addition there will be rapid deterioration of copper cable at the point of leak. The work lead should be connected to the piece being welding within three feet (0.9m) of the point of welding

TYPES OF UNDER WATER WELDING

WET WELDING
Welding is performed under water directly exposed to the wet environment

DRY WELDING
Here a dry area is locally created around the portion to be welded or chambers are created and welder performs welding by staying inside it.

Wet welding
Wet welding is mainly used for emergency repair works. Simplicity, speed and low cost make this method highly desirable. Shielded Metal Arc welding is employed Welder has to encounter with the unstable under water conditions and should be well insulated from the surroundings.

Principle of operation of Wet welding

The worktop be welded is connected to one side of an electric circuit, and a metal electrode to the other side. These two parts of the circuit are brought together, and then separated slightly. The electric current jumps the gap and causes a sustained spark (arc), which melts the bare metal, forming a weld pool. At the same time, the tip of electrode melts, and metal droplets are projected into the weld pool. During this weld operation, the flux covering the electrode melts to provide a shielding gas, which is used to stabilize the arc column and shield the transfer metal. The arc burns in a cavity formed inside the flux covering, which is designed to burn slower than the metal barrel of the electrode.

Wet welding process

Arc column is generated between the electrode and work piece. The flux coating is designed to burn at a slower rate compared to the core electrode metal Shielding gas is evolved from the electrode coating.

Arrangement for Wet welding

Disadvantages of wet welding

Poor visibility of the weld Hydrogen induced cracking Rapid cooling of the weld result in reduced toughness and ductility

Dry welding
Advantages
A dry chamber is created near the area to be welded. Welding is performed in the chamber. Good weld quality. Better arc stability.

Type of dry welding

COFFERDAM METHOD
A chamber is constructed around the structure to be welded Chamber is open to atmosphere at its top side The pressure inside cofferdam corresponds of the surface

HYPERBARIC METHOD
A chamber is sealed around the area to be welded. The welder can stay inside the chamber. Water from the chamber is displaced and filled with Helium and Oxygen mixture. Bottom side of the chamber is open to water.

HYPERBARIC CHAMBERS

LOCAL DRY OR CAVITY METHOD Here the portion to be welded is made dry locally. A trumpet shaped nozzle is used through which water jet passes. Avoids the need for a habitat chamber

LIMITATIONS OF DRY WELDING

Complexity in construction of welding chambers Difficulties in providing effective sealing Effect of pressure under greater depths

DEVELOPMENTS IN UNDER WATER WELDING

Wet welding has been used as an underwater welding technique for a long time and is still being used. With recent acceleration in the construction of offshore structures underwater welding has assumed increased importance. This has led to the development of alternative welding methods like friction welding, explosive welding, and stud welding. Sufficient literature is not available of these processes.

RISKS INVOLVED
There is a risk to the welder/diver of electric shock. Precautions include achieving adequate electrical insulation of the welding equipment, shutting off the electricity supply immediately the arc is extinguished, and limiting the open-circuit voltage of MMA (SMA) welding sets. Secondly, hydrogen and oxygen are produced by the arc in wet welding. Precautions must be taken to avoid the build-up of pockets of gas, which are potentially explosive. The other main area of risk is to the life or health of the welder/diver from nitrogen introduced into the blood steam during exposure to air at increased pressure. Precautions include the provision of an emergency air or gas supply, stand-by divers, and decompression chambers to avoid nitrogen narcosis following rapid surfacing after saturation diving. For the structures being welded by wet underwater welding, inspection following welding may be more difficult than for welds deposited in air. Assuring the integrity of such underwater welds may be more difficult, and there is a risk that defects may remain undetected.

SCOPE OF FURTHER DEVELOPMENTS

The technology for hyperbaric welding is well established and generally well researched. There is however a need to be able to use a process at even greater depths, research being carried out for welding at a range of 500-1000m deep. THOR-1(Tag Hyperbaric Orbital Robot) is developed where diver performs pipe fitting, installs the track and orbital head on the pipe and rest process is automated. Developments of driverless hyperbaric welding is an even greater challenger calling annex developments like pipe preparation and aligning, automatic electrode and wire reel changing function, using a robotic arm installed. This is in testing in deep waters. Explosive and Friction welding are also tested in deep waters

APPLICATION
Offshore construction for tapping sea resources Temporary repair work caused by Ships collisions, unexpected accidents. Salvaging vessels sunk in the sea. Repair and maintenance of ships Construction of large ships beyond the capacity of existing docks

CONCLUTION

Under water welding provides a means of assembly or repair under water. The present difficulties in under water wet welding can be eliminated with Hammerhead wet spot welding that can be employed for better welding. Further developments in dry welding to greater depths can ensure better utilization of sea resources.

REFERENCES
BOOKS
1) D. J Keats, Manual on Wet Welding. 2) Annon, Recent advances in dry underwater pipeline welding, Welding Engineer, 1974. 3) Lythall, Gibson, Dry Hyperbaric underwater welding, Welding Institute. 4) W.Lucas, International conference on computer technology in welding. 5) Stepath M. D, Underwater welding and cutting yields slowly to research, Welding Engineer, April 1973. 6) Silva, Hazlett, Underwater welding with iron powder electrodes, Welding Journal, 1971.

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