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+48 95 762 08 61
Modern technologies of metal working
Laser beam cutting
Laser cutting of tubes and sections
Robotic welding
Sheet metal bending
+48 95 762 08 61
Laser beam cutting
Laser cutting of tubes and sections
Robotic welding
Sheet metal bending
Underwater welding is one of the most demanding and spectacular fields of engineering, combining advanced welding technologies with extreme working conditions in an aquatic environment. This unique specialization plays a key role in maintaining marine infrastructure, repairing ships, and carrying out ambitious underwater projects worldwide.
The origins of underwater welding date back to the early 20th century, when Russian engineer Konstantin Konstantinovich Khrenov carried out the first successful electric welding tests under water in 1932. A breakthrough came with the development of wet welding, where the process takes place directly in contact with water, and dry welding, performed in special gas-filled chambers.
World War II significantly accelerated the advancement of this technology due to the urgent need for wartime ship and port infrastructure repairs. In the 1950s and 1960s, with the expansion of offshore oil and gas industries, underwater welding gained commercial importance, becoming essential for the exploitation of continental shelf resources.
Underwater welding is extremely complex from both a physical and chemical standpoint. Water presents multiple challenges—it is an excellent heat conductor, which means temperature in the welding zone dissipates quickly. In addition, during welding, water dissociates into hydrogen and oxygen, potentially creating gas bubbles in the weld and reducing its quality.
Hydrostatic pressure increases by about 1 atmosphere for every 10 meters of depth, affecting the behavior of the electric arc and molten metal. At greater depths, welders must also cope with nitrogen narcosis and decompression, which complicates and lengthens the work process.
Wet welding involves immersing the welding electrode directly in water. The electrode is coated with a special material that creates a gaseous shield around the welding arc, protecting it from direct contact with water. Main advantages include:
Disadvantages include limited weld quality due to rapid cooling and difficulty in controlling welding parameters.
Dry welding is carried out in specially designed welding habitats filled with protective gas. These chambers can be rigid (welding habitats) or flexible (pressurized suits). This process ensures:
However, dry welding requires more complex and expensive equipment and precise logistical planning.
This intermediate method keeps the welder’s head in a dry environment while the hands operate in water using special chambered gloves. It provides a compromise between efficiency and weld quality.
Underwater welding requires specialized equipment resistant to seawater, pressure, and corrosion. The essential gear includes:
Welding power sources – completely waterproof and protected against short circuits. Modern welding generators feature automatic shutoff systems for fault detection.
Specialized electrodes – coated with multilayer compounds that stabilize the arc and generate protective gases and slag. These coatings must withstand water exposure and ensure stable arc performance.
Diving systems – ranging from simple air-supply sets to advanced mixed-gas systems for work at great depths.
Welding chambers – for dry welding, equipped with atmosphere-control, protective gas supply, and parameter-monitoring systems.
Working underwater involves numerous hazards requiring special attention and preparation. Electric shock is one of the most serious dangers—even minor insulation damage can be fatal underwater. Modern welding systems are therefore equipped with current-leak sensors and automatic safety shutoffs.
Gas explosions are another serious risk. During underwater welding, hydrogen and oxygen are released, which in the right proportions can form explosive mixtures. Welders must be trained to recognize warning signs and follow safety procedures.
Decompression is a constant challenge for welders working at great depths. Sudden ascent can cause decompression sickness, so every dive must be carefully planned with appropriate decompression stops.
Underwater welding has wide applications across marine industries:
Oil and gas industry – repair and maintenance of drilling platforms, subsea pipelines, and extraction systems. Underwater welders are essential for installing new pipeline segments and repairing corrosion or mechanical damage.
Shipbuilding industry – repair of hulls, propellers, rudders, and other structural elements without the need for dry-docking, saving time and costs for shipowners.
Port infrastructure – maintenance of quays, piers, breakwaters, and other port structures, enabling repairs without interrupting port operations.
Power plants – repair of cooling systems, water pipes, and other submerged components.
Marine archaeology – stabilization and preservation of historically significant shipwrecks.
The quality of underwater welds is critical to the safety of marine structures. Various non-destructive testing methods are used underwater, including ultrasonic thickness testing, penetrant inspection, and adapted radiographic methods.
International standards such as AWS D3.6 (American Welding Society) and ISO 15618 specify requirements for underwater welders’ qualifications, welding procedures, and quality control. Welders must regularly renew certifications and undergo further training.
Becoming an underwater welder involves a long and costly training process. Candidates must first qualify as commercial divers and certified surface welders. They then complete specialized underwater welding courses covering:
Certification is issued by accredited training centers and requires passing theoretical exams and practical welding tests at various depths.
The future of underwater welding is closely linked to automation and robotics. Remotely operated underwater welding robots can work at depths inaccessible to humans and perform precise welds under extreme conditions. Augmented reality technologies assist welders in visualizing their work underwater.
New welding materials and protective coatings improve weld quality and extend the lifespan of underwater structures. Research on underwater laser welding opens up possibilities for even better results.
The growth of offshore renewable energy, including wind farms and floating power plants, creates new job opportunities for underwater welders. The increasing importance of sustainable development highlights the need for durable, long-lasting underwater structures.
Underwater welding remains one of the most demanding technical specializations, merging advanced welding expertise with technical diving skills. Despite technological progress, human expertise is still indispensable. Underwater welders form an elite group of specialists whose knowledge and abilities ensure the safety and functionality of critical marine infrastructure worldwide.
With rising demand for offshore renewable energy, deep-sea exploration, and the development of underwater technologies, underwater welding will play an even greater role in the future. Investment in research, training, and new technologies is key to the continued advancement of this fascinating engineering discipline.