The process of underwater welding defies logic. Can you imagine electricity flowing through water and leaving the welder unscathed?
Underwater welding functions similarly to topside welding, even though the environment differs. Underwater welders take the risk, but less than you think. The underwater welding process is misunderstood, leaving rumors and open-ended and untrue explanations. Before understanding how this type of welding functions, getting the basics of surface welding is crucial.
When you think about underwater welding, what gets to your mind?
The underwater welding suit, surrounded by firing electricity and water at the metal gap, could require repair. The welder is either performing hyperbaric or wet welding. Each welding process is slightly different; these procedures borrow principles from surface welding but employ them differently.
You can also check how to become an underwater welder.
Underwater Wet Welding Process
The sites have water surroundings. However, this does not mean they have direct water exposure in the whole process. It creates gaseous bubbles that keep the site shielded temporarily. The shield comes from the flux when melting on the electrode. It is made up of seventy percent of hydrogen. As the flux melts, it will cover the weld site and protect it from water during the cooling process. Nevertheless, even with protection, water has effects on the weld.
Since the electric arc creates immense heat amounts, it sprays thousands of bubbles while welding. More than the annoyance, the bubbles may blind the welder and make it hard to see the site of the weld. As underwater welding is pretty difficult, So they get a handsome amount of wages.
Do you want to know how much does an underwater welder make? Well, they get $38k- $300k based on their experience.
Under Water Hyperbaric welding process
Also called dry welding, hyperbaric welding offers a weld site that gets insulated from the water. The insulation gets accomplished through a barrier full of gas.
The procedure is similar to topside welding, with several exceptions. This process occurs under extreme pressure, approximately 0.7% pounds per inch or more. Pressure must increase to keep the air volume constant and set the ratio to the surrounding amount. This welding process is carried out in a pressurized underwater habitat.
The habitat might fit around the site of the weld or even expand up to one room’s size. This procedure can be costly. More significant habitats are expensive and cost more money for purchasing and upkeep.
Additionally, maintenance while being used will rack up the bill because it supplies constant electricity and gas to the welder.
Finding tools for your underwater welding project can be a daunting task. There is so much that needs to be put into consideration.
They include:
- Function
- Purpose
- Quality
Welder divers require the right items to do their job accurately, safely, and efficiently. This guide will help you navigate the process of selecting underwater welding equipment.
Underwater Welding Equipment
Every welding job is quite different. Their tools and soot must be versatile and can take significant abuse. Because many underwater welders weld the topside, it is crucial to understand how their tools work differently in marine environments.
To weld the underwater properly, the commercial diver requires five significant tools:
- Power supply
- Stinger Electrodes
- Diving suit
- Accessories
- Diving helmet
Diving helmet
These are ears and eyes for hyperbaric welding tasks. The welder needs a helmet that is reliable for the job. From the surface, the hood of the helmet protects the face and eyes of the welder during the job. Helmets save this role, allowing for breathing for the diver.
Many use the same helmet they would go during regular commercial diving with one addition. The welding screen attached to the mask front is for protecting the eyes. Some welding screens flip down or up like a hood and come in different shades.
Types of diving helmets
Underwater welders use these helmets according to the project.
Open Circuit
This helmet employs a non-return gas valve, side weights, an anti-fogging lens, new characteristics, and an inner cushion. It is a very popular and standard helmet for divers doing it on commercial bases. Since it utilizes the non-return valve, the air you expel goes to water.
Reclaim
This type of helmet follows similar principles to the open circuit but recycles the diver’s exhaled gas and gets it back to the system at the same pressure.
Free-Flow Helmet
Outfitted with simplistic designs, the helmet is characterized by large transparent visors for greater visibility. Due to its simplicity, the diver takes it apart and puts it together with the help of a wrench and screwdriver. It is employed for shallow water and hazardous materials.
Wet welding only utilizes surface-supplied air; therefore, it is worth mentioning that the equipment utilized in SSA is specialized and is only used by professionals. SSA is vital for underwater welders because it enables communication with the welding machine’s surface team.
Accessories of underwater welding
In addition to the helmet, welders require necessary attachments and accessories.
Diving Knife
Just like the whip is crucial to Indiana Jones, so is the knife to the welder diver. It is essential for many situations, whether they want to cut in the project material, free themselves from entanglement, or wedge open a door. The diving knife does this job.
Umbilical cord
This is where the gas gets pumped to and from the surface to the welder.
Harness
This is crucial to keep the diver buoyant and in one area while doing their work.
Compressor and gas panel
A qualified team monitors the gas gauges and maintains a steady supply of air coming to the underlying diver. Divers monitor them directly. Many employ low-pressure gas because of low maintenance and an unlimited air supply.
Bailout Gas
Utilized for emergencies, this gas gets carried by divers as a secondary source of gas supply in case the SSA equipment fails. It appears in the form of minor scuba tanks.
Knife Switch
The knife switch is not similar to the diving knife. It is utilized while using underwater electric equipment when welding. Constructed like a simple lever, it controls the electricity floor from the topside to provide power to your tools.
Diving Suit
The diving suit is a flexible armor for your task. What is the difference between a scuba diver’s suit and an underwater welder’s suit? It depends on the activities you do. Many commercial divers employ the drysuit because it offers more protection and superior climate control than the wetsuit.
Depending on your diving environment, the drysuits are shell, rubber, or neoprene.
Nevertheless, several underwater welders put on coveralls on top of suits as an additional external protection layer. If molten metal comes in direct contact with the suit, it can burn through.
Coverall is vital for this task. To protect hands, the welder puts on rubber,
thick linemen gloves on top of several latex pairs.
They can snap a rubber band on the wrist section to keep water from getting to the gloves.
Respirators
A respirator is crucial and is often overlooked as equipment for welding. Hot metals can release toxic gasses into the air, particularly zinc and magnesium fumes. The fumes can result in Parkinson’s-like symptoms, asthma, lung cancer, and hearing loss. Individuals skip respirators because they cannot find a fitting model under the welding mask. Invest in looking for low-profile, small respirators that fit the mask.
Improper use of respirators is dangerous. Respirators only work with proper air supply or filters. Ensure that the respirators you purchase match the material types you are working with. Always ensure the respirator is fitting and sealed; otherwise, it will not protect you.
Hands, chest, and arms
Your hands, chest, and arms are the closest to the fire line for the molten slag and sparks. There is no need for satisfying dexterity while picking the safety gear. Depending on the job, you will require a welding apron or a full welding jacket with different welding sleeves. Gloves are necessary for all types of welding.
Waterproof Electrodes
The electrode is a crucial part of underwater welder tools because it provides material for welding. There are many materials and sizes to select from, from the small 1/8-inch welding rods that work on mild steel to a larger 5/32 stainless steel rod.
The main difference between underwater welding and topside is the coating; marine electrodes must be extremely water-resistant. Some divers coat their electrodes, but many of them last for more hours.
They work perfectly well for depths that go up to thirty-three feet. Below that level, the pressure will cause added porosity that can damage the structure’s integrity.
Water Resistant Coating
It would be better if it could hold up for long in the hostile marine environment.
High Strength Yield
Materials of better quality inside the electrode provide high-density weld that can last long. Typical diameters are 5/32 and 1/8 inches.
Underwater Stinger
When it comes to the marine stinger, less is more. They hold electrodes and are primarily manufactured from lightweight plastic, reducing the possibility of fatigue and cramps.
Underwater welders that train with particular stingers always prefer using the same type while at work, even if a newer model exists in the market.
It would help if you stuck with what you know as a consensus. This is due to the feeling that other job sections could be more predictable.
Nonetheless, updated equipment assists the dive in being safer, having an efficient operation, and helping reduce overall costs. This equipment makes these tool types cutting edge, especially the underwater torches. An underwater stinger of high quality has the following physiognomies.
Insulated
Saltwater is a great conductor of electricity, and welder divers require all the necessary protection from this. If the stinger has good insulation, it will keep welder divers from feeling the current even at two hundred amps.
Lightweight and ergonomic
The bigger the project welding, the more the underwater welder requires a stinger that can hold for a long period.
Angled Correctly
The stinger requires the perfect notch and hole where the underwater welder can put in the electrodes. It allows for optimal use in various positions of welding and distinguishability.
Underwater Welding Machine
Current and amperage matters when it comes to the welding machine. Counter to many topside welding processes, controlling marine welding equipment works well with the control team and the divers below the boat. Immediately before the diver starts welding, they will communicate to the control team through the radio.
This provides a signal to turn underwater welding machines to the right amperage.
The required power is dependent on the electrode size. Since most welding is done on top, a few companies formulate welding machines made explicitly for underwater welding. Some need additional steps to change to an output mode safe for underwater use, like removing the coil from the internal of the machine.
These are the qualities you need to look for in the power source of underwater welding.
Stable and consistent power
The right machine does not fluctuate in amps without the knob being changed, even with long power cables; it has to maintain the best, continuous flow.
Duty Cycle
The duty cycle represents when the underwater welder can operate the underwater welding equipment at maximum power or amperage. If the machine operates at 275 amps for a sixty percent duty cycle, you can weld the full throttle for sixty minutes out of ten minutes. Other machines can work at a higher level, but the power requirements depend on the electrode type being used.
DC, not AC
In water, all welding equipment needs to get powered through direct current and not alternating current. Since direct current flows in one direction, it is the best alternative to alternating current underwater. The divers utilize negative or straight polarity that offers a long life for the electrode holder.
How to use the welding equipment rightly
Welding may produce hazardous gases to your health during the process of welding. Therefore, the welders must avoid breathing these gasses and fumes and keep the head from the fume. Additionally, you must wear clothes resistant to flames, such as a shirt and denim pants made from a woven material or a special welding jacket. Additionally, it would help if you remembered not to wear sports shoes because they can smoke, resulting in a burning sensation.
The instructions of the manufacturer come with all welding equipment. They contain crucial safety info and informational procedures that maximize the machine’s potential; therefore, users must read, understand, and follow those safety practices carefully.
When the welder is working, the work circuit is hot to the extent that it can produce electricity. Therefore, avoiding hot parts with wet clothing and bare skin is crucial since the electric shock can result in sudden death. Other things are safely maintaining the electrode holder, welding machine, welding cable, and work clamp. While working above the floor level, people have to employ the safety of the welding equipment, like using the best equipment for protection in the event they unexpectedly fall. Always remember to replace insulation that is damaged.
Welding gets applied in very many fields in the industry. Nonetheless, it will result in dangers and injuries if the users or welders need to learn how to select the right safety equipment and methods of avoiding unexpected accidents. The welder must be aware of utilizing the safety of the welding equipment.
Armed & Ready
The tools above come at a sizable cost, but many of those welders get employed by a firm with this equipment.
If you do not have this luxury, it becomes possible to base the expenses of your tools on your income and invest where possible.
Expenses that are tax deductible will help you succeed as an underwater subcontractor. Besides the electrode and stinger, the tools of the underwater welder are used for these purposes besides welding underwater. It is still important to know the characteristics of the equipment to ensure that you remain informed and use the best for underwater welding jobs.
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