Available online at wwww.sciencedirect.com nee . . Souctuolnegty “eh ScienceDirect Procedia FLSEVIER rosea Str! ney 272020) 14-21 srw clever comlocate proce 6th International Conference on Industrial, Mechanical, Electrical and Chemical Engineering (ICIMECE 2020) Recent Developments on Underwater Welding of Metallic Material Eko Surojo, Ericha Dwi Wahyu Syah Putri, Eko Prasetya Budiana, Triyono” Department of Mechanical Engineering, Universite Sebelas Maret, Surakarta 57126, Indonesia Abstract different metals which are carried out underwater. This process is Underwater welding isthe process of connecting two similar. applied in various construction of engineering materials both on land and underwater environments such asin ship construction, ol and gas mining inthe middle ofthe sea and nuclear power plants, Material construction greatly influences the method suitable for the welding process, It will affect the evolution ofthe microstructure und mechanical properties ofthe material. So, twill affect the results ofthe welded joint © 2020 The Authors, Published by Elsevier BL. This is an open access article under the OC BY-NC-ND license (hp /reativecommons.orlicenseslby-ne-ndl.0) Peer-teview under responsibilty ofthe organizes of ICIMECE2020 Keywords: Underwater wolding; pplication of underwater welding; the affect of weld join 1. Introduction ‘Welding is a method of joining the process of materials, especially metal materials that have been carried out for xyears with implementation, eg., on land-marine structures (Bae et al., 2016a, b) and transportation modes (Cao etal, 2016; Muttagie et al., 2019). This process is carried out by joints two similar or dissimilar metals by heating to melt the parts together, then allowing them to cool and may be joined together. The welding process can be carried out in 4 variety of engineering materials construction, either on the land or water environment (Yohanes et al., 2018). ‘Underwater welding is generally used to repair and maintain pipeline construction on the underwater, ship components, port construction, and the structure of nuclear power plants (Guo et al, 2015). The method used underwater welding * Comeeponingsuthor. Tel: +62-122-68-8865; fx: +62-120-028-86, Femail addres: iyono?4@stallunsacid 3216 © 2020 The Authors, Published by Elsevie BY. This isan open eccren atte unde Uns OC BY.NCND lena (kp eeativecommons.og/lensee/by-6-/4.0) Peeczeview under responsibility of the organizers of ICIMC#2020 10 1016/3 prot 2020-0703ho Surojo et a /Procedia Structural Integrity 27 (2020) 14-21 15 consists of Shielded Metal Arc Welding (SMAW), Flux-cored Are Welding (FCAW), and Gas Tungsten Are Welding (GTAW) (Labanowski, 201 1; Barnabas et al, 2020). This method is determined mainly in cases of urgent repair the structure (Doyen et al, 1992). Dry welding and wet welding are the working principles of underwater welding (Majumdar, 2006; Orr, 2006; Taylor and Jerzy, 2011). However, this technique has advantages and disadvantages that vary, so there is a need for consideration before the welding process is carried out. Dry welding is an underwater welding process by using a dry chamber which serves to protect the are welding and weld metal from the water around the welding area (Labanowski, 2011). This technique can produce welding quality that is almost equivalent to the results of welding on land (Rodriguez-Sanchez et al., 2014). Dry welding uses a special chamber (dry chamber) which is conditioned in a dry ‘environment so that the arc welding is more stable (Yang et al., 2019). The dry chamber in the welding process has a ‘weakness are a space for a welder to be limited, and the cost for @ dry chamber is expensive. Besides dry welding, wet welding is a method that uses special stick electrodes because the material and welding electrodes must be directly contacted with water in the weld area (Majumdar, 2006). Wet welding has the advantage that the operation process is relatively simple because it does not require many prepare and the motion space of the welder is unlimited. Therefore, the cost required is relatively cheaper than dry welding (Orr, 2006). Wet welding has many adverse effects, such as, decreasing the mechanical properties of the material, increasing the cooling rate of the underwater welding joints, increasing the welding porosity slag trapped in welds, and changing in the chemical composition of weld results (Pursama et al., 2018; Chen et al, 2020). ‘The metallic material is a material that is often used in engineering construction. If the material isthe process of joining by welding, the material will change in the microstructure and mechanical properties of the material (Guo et al,, 2015). Gao etal, (2016) examined the microstructure and mechanical performance of underwater wet welded S355 steel. Itcan apply to marine structures. Pedati etal. (2017) conducted a study on $0S2-AA workpieces that were welded using the FSW technique in underwater and in water. The differences in the mechanical properties and microstructural features of both joints, Based on the explanation above, itis necessary to discuss the materials that will be used in underwater welding specifically for metallic materials, To become a comprehensive and easily understood material, a review ofthis article ‘was carried out, This review is expected to be a reference in mapping underwater weld joint research, making it easier for researchers to find out the characteristies of the material used in underwater weld joins, 2. Underwater welding Underwater welding is a material welding technique using special equipment that is carried out underwater. Underwater welding was discovered by Konstantin Khrenov in 1894, At that time, Khrenov was studying electrical ‘welding, engineering, and mathematics. He was teaching and researching at Saint Petersburg State Electro-Technical University (ETU) (Bamnabas et al, 2020). He believes that this welding technique is considered the most effective ‘way to repair damage to the ship. In recent years, the development of marine resource exploitation and utilization is driven so rapidly. Most ocean engineering structures have main components submerged in sca-water, so the research ‘on underwater welding is essential for the offshore industry (Chen tal, 2018; 2020), Underwater welding is classified into two based on welding techniques, namely dry and wet welding (Majumdar, 2006; Orr, 2006; Taylor and Jerzy, 2011). The difference between dry and wet welding, which one of them is the condition of the welding area (Chen et al., 2018). Dry welding is an underwater welding technique by using a dry chamber welding component, so arc weld is not in contact with water around the welding area (Labanowski, 2011). Wot welding is a welding technique that direct contact with water in the environment around welding (Majumdar, 2006). Dry welding is an underwater welding process by using a dry chamber or dry hyperbaric chamber (Barnabas et al, 2020). Dry welding conditions, as shown in Fig. La. The dry chamber is considered to protect the welding are weld. Ifthe welding arc is stable, the welding metal will increase strength and tenacity, high corrosion resistance, and 4 small amount of hydrogen gas produced during the welding process (Hu et al. 2018). But, the presence of the dry chamber in the welding process has a weakness because the space for a welder to be limited, the equipment may be costly and complicated (Bumer, 1978). Wet welding is a welding process using special stick electrodes (Majumdar, 2006). The base metal, electrode, and welder must be contacted directly with water around welding (Fydrych et al., 2013). Wet welding conditions, as shown in Fig. 1b. Wet welding has the advantage that the operation process is6 [Bto Swrojo et at. /Procedia Souctural Integrity 27 (2020) 14-21 simple because it does not require a lot of special preparation and unlimited space forthe welding operator. Therefore, the cost required is relatively cheaper than dry welding (Orr, 2006). However, direct contact of wet welding with water ‘can cause some negative impacts such as the arc flame being unstable, decreasing the mechanical properties of the ‘material, and can increase the cooling rate of the welding material (Swierczynska et al., 2017). ig 1. The condition of underwater welding: (a) ry welding (Maju, 2006), and () wet welding Nixon, 2000), Underwater welding technique is an appropriate technique for emergency repairs inthe event of structural damage inthe middle ofthe sea that does not allow dismantling fo be caried inland. So that welding is considered to save time, energy from workers, ané costs (Orr, 2006). Wang etal. (2017) argue that underwater welding can serve to repair and maintain underwater structures that are generally used in ship construction, ol, and ga piping offshore and nuclear power plants. However, underwater welding can have a negative impact inthe form of defects in welding material. It caused by trapped hydrogen gas in the weld metal, which can have a detrimental effect in the form of cracks, which can reduce the reliability of welding structures and cause ste! to become britle and broken (Chen ct al, 2020). Chen tal. (2018) argue that the effect of water depth on are behavior, ar bubble characteristics, and welding performance on the UWW FCAW process. The results show thatthe depth of the water decreases the size ofthe droplet, stability of are weld, and produces a lot of pores on the weld metal. So, itis necessary to consider inthe selection of appropriate techniques for repairing underwater structures. Articles SMPs ge sash se SP My Saghey oe Years Fig. 2 Underwatar welding esearch, Fig, 2 shows many articles about underwater welding from 2001 to 2020 that experienced fluctuations. The topic of discussion of underwater Welding in this period was very diverse, including the development of welding technology, ‘weld metal microstructure, mechanical properties, any elseSo that the focus of the discussion is comprehensive, the-Bto Soo eta. /Procedia Souctral Integrity 27 (2020) 14-21 ” selection of appropriate topics is referred. Table 1 summarizes some rescarch articles about metallic materials use in underwater welding, ‘Teble 1, Research antles abou undersater welding f male material, Tina No Seto Mesa Motto Tene Meanie Paperiee Tawra (2010) S519 Aluminum revon sae The refined pra smuvtres, The enile stength of We Alloy welding highedenstydisocstions and—normalized material is 31SMPs, hanes solid soliton and afer ndervater welding suength effect syuthetcally led process is MIMP. to the increase of hardness of MIIL, and thus improved the tensile strength of the underwater join 2 Dhangetal 2012) 2219-T6 Aluminum —fieson sie NHAZ. ares forms deposits with The minimum hardness value of| Alloy welding adinmeterof 106428nm witha UMA (Underwater 1IAZ) ie thickness of 10-4 26nm while 92H, while NHAZ. (Normal deposits inthe UHAZ aes have HAZ) THY. 92:30 and 721m diameters, 3S Cuietal 014) $355 steel Frcs ayer Inthe TIAZ area, there are slot Maximum tensile strength and phigwelding of ith inte and 2 feo impact energy at V-notch found Acicular Fete, polygonal SOOMPa and 39.5} in welded ‘art, and martensite, joints with ASEN axial free 4 Bailie al 2015) $275 sel Frcs sie The underwater structure is Longtinal tensile strength at welding rmore dominant in the form of the average yield strength ie regular Fete Granules. due 47SMPa, andthe ultimate to the rapid cooling of UWW strength is 377M 5. Podapat etal 5082 alaminam —_ficsnsir——The faction ofthe void aca in The average hardness of orn alloy welding the 82 of underwater FSW is underwater FSW increases 21% decreases in a higher number greater than the normal FSW, than pormal FSW. I is and $3% greater than is Base iminthed 3.6% in the SZ of Material BM), roma FSW snd 1.3% in the “underwater FSW sti 2000 6 Tanta. 2017) AA3008ahinam —frietin sir The sizeof ecrysllzed gains The fracture morphology was alloy welding vas approximately 2.26um and constituted ofa lage number of 233m whereas, in °C water, deep dimples. When the the sizeof recrystallized grains annealed hot band was welded decreased 1 120, and in OC wate, the actu 1.23pm for the hot basd and morphology wat a large number snnealed ot band of shallow dimples whereas, in tie condition, the depth of the dlinples gradually increased. 7 Wetal. 2018) B40 Stet Nuxcored are There ae many microstructures Ulimate tensile strength and welding fof Lath Martensite with impact strength increase during diferent ypesthat dominate the procest of cod soko, (CHAZ aca, due to many alloying elements (ee, Fe, Mi, and C0, 8. Muayat etal Low carbon steel shielded metal Air welding i dominated by Weld meal op UWW joints ata 2020) ss4o0 arewelding ——Polygonal Ferite (PH) and depth of 10m has a higher fain boundary fete (GBF) hardness value of around Phases, LWW witha depthof 36SHV. There are many 25m i6 dominated by GBF structures of AP (Aecievlar tnd PF, while depths of Sand Fete) caused by apd cooling mar dominated by AF and FSP (Ferte with Second Phase aligned18 [Bto Suro eta. /Procedia Souctural Invert 27 (2020) 14-21 9. Chenetal (2020) Lowearbon 235 selfshielded In the CGHAZ area, there ae High strength low alloy E40 steel and high fux-cored some LM (Lath Marensit) and stel plate has a higher cack strength low allay wire ‘AM (aiclar martensite) inthe sensitivity value than low 0 ste! pate {ow cathon QU3S steel while in carbon Q23S see mater the high strength low alloy E40 stel plat, thre are some SPF (side plate fewite) and AF (Acicular Fete 3. Metallic material ‘The metallic material is a material that has special properties that engineers usually use for engineering. Metallic ‘materials are classified into two, namely ferrous and nonferrous metal (Callister, 2003). Ferrous metal is 2 metal that has the central element in the form of iron (Fe). This material is mainly used in the construction of engineering, e.g., powerplant equipment, shipbuilding, bridge construction, and other components. The nonferrous metal is a metal that contains little or no essential elements in the form of iron (Fe). Alloy elements from nonferrous metal materials are Copper (Cu), Aluminum (Al), Magnesium (Mg), Titanium (Ti), and others (Xue, et al., 2019). The alloying elements ccan affect the resulting weldability. Ifthe elements are added to nonferrous materials, special methods are required for the welding process Fyaryeh et al. (2013) research on weldability for ferrous metal. The material $355J2G3 in water condition while 'S500M steel in air and water condition. The welding process with MMA Process, Composition of chemical contained ‘on material $355J2G3 and SSOOM steel, as shown in Fig. 3, The $355J2G3 steel consists of different Ferrite and Pearlite structures, while the S500M steel structure consists of several Ferrite grains of very different sizes and Pearlite structures, 100, as shown in Fig, 4. 8 e 017 eens ion som) y C008 al som 7) nee” Po A ca. 044 Al oss 1, 0.039. 002 15,0001 v, 0.054 WN ~ SX - xs,0056 WN Fig. 3. Composition of chemi! contained on $35512G3 and S500M ste! woiht %)(Fydryeh et a, 2013) rs Fig, Microstructure fom $35S12G3 and SSOOM see (Fydryh et, 2013),ho Surojo et a /Procedia Structural Integrity 272020) 14-21 18 ‘The result of this research is the hardness value of underwater welding $355J2G3 steel joints up to 400 HV10, Higher carbon content in this steel in association with an increased cooling rate of the joints resulted in the HAZ arca (Zhang ct al, 2016). Furthermore, at the carbon equivalent Ce = 0.44% for $355J2G3 steel, led to forming quench structures. Specimen of $355J2G3 steel has a characteristic for initiating cracks in the fusion line, which is confirmed by the presence of britle structures in this area. Whereas, the hardness value in base metal S500M is 200 HV10. After the welding process in the air environment, the hardness value on tae HAZ at the S500M welded joint increased to 24OHLV 10 while the hardness value of the underwater welding joint of this material increased by 40%. The low carbon content in the steel as well as carbon equivalent (Ce = 0.30%). This situation can indicate that low-carbon steels after thermo-mechanical processing is applicable for marine and offshore engineering structures when underwater welding is required. ‘Shnavas et al. (2018) investigated the weldability of marine grade AA $052 aluminum alloy by underwater friction stir welding. Marine-grede aluminum alloys are used in aerospace, marine, and automobile industries. This material ccan use an altemative to stee! because the characteristics are lightweight, good formability, functional strength, and high corrosion resistance. This research used high-strength aluminum-magnesium alloy AA $052-H32. The welding ‘equipment and the process parameters used both for underwater FSW and normal FSW were the same. Photographs ‘of the fabricated with different tool rotational speed for underwater FSW joints are shown in Table 2. ‘Table Poses parameters of fbvicaod(Shnavas et sl, 2018), Process z z 7 = Toot rational speed TB) 500 co 75 co 0 ‘The sufficient heat input at FSW is necessary for dynamic recrystallization, Therefore, the strain rate controls the grain size at lower rotational speed or higher welding speed, whereas heat input controls the grain size at higher rotational speed or lower welding speed, So, the results in grain size increased. Grain size will affect the value of maximum tensile, Based on the welding results shown in Fig. 5, The optimum process parameters for achieving ‘maximum tensile strength by normal FSW compared with underwater. The maximum tensile strength both underwater and normal FSW at tool rotational speed of 700rpm produced 208.9 MPa and at 600 rpm produced 200.3MPa. It ‘means the maximum tensile strength obtained by underwater FSW is about 2% greater than normal FSW. The absence of the HAZ region found in the underwater FSW process, which might be duc to water cooling, Ifthe water cooling inereases, the ultimate tensile strength will increase. Furthermore, it found finer equiaxed grains at Stir Zone (SZ) of the welded plates by underwater FSW process than the normal FSW process. HAZ is an arca ‘where crack propagates in high-strength welded joints. The absence of this area found in the underwater FS welded plates due to faster heat dissipation during water cooling. Therefore, the plates welded by the underwater FSW process showed high resistance to fracture compared to the normal FSW process. E 2 Underwater FSW ‘Tool rotational speed (rpm) Fig 5. The comparison sil strength of underwater FS and normal FSW (Shnavas et, 2018),20 [Bto Surojo etal. /Procedia Souctral Integrity 27 (2020) 14-21 4. Conclusions ‘The application of material uses in marine, and offshore engincering structures is of particular concem. The underwater welding process can affect the base metal composition and mechanical properties that occur atthe joint of the weld metal. The chemical composition that changes can affect the welding capability in underwater welding, e.g., as an additional carbon content, If the carbon in the material increases, so the weldability will decrease, The high ‘carbon content in the material will cause the mechanical properties of the material to become hard and brittle. Furthermore, water temperature produces high cooling rates and finer microstructures with high hardness. 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