Research Advances in Underwater Welding Technologies and Applications: A Review

doi:10.11900/0412.1961.2025.00202

Acta Metall Sin

2026, Vol. 62

Issue (1): 81-99 DOI: 10.11900/0412.1961.2025.00202

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Research Advances in Underwater Welding Technologies and Applications: A Review

WANG Zhenmin¹, ZHUANG Jianpeng¹, HE Zhiyu¹, WANG Yuhai¹, CHI Peng¹, ZHANG Bin¹, ZHANG Qin², LIAO Haipeng³(

)

1 School of Mechanical and Automotive Engineering, South China University of Technology, Guangzhou 510641, China
2 School of Computer Science and Engineering, South China University of Technology, Guangzhou 510006, China
3 School of Marine Science and Engineering, South China University of Technology, Guangzhou 511442, China

Cite this article:

WANG Zhenmin, ZHUANG Jianpeng, HE Zhiyu, WANG Yuhai, CHI Peng, ZHANG Bin, ZHANG Qin, LIAO Haipeng. Research Advances in Underwater Welding Technologies and Applications: A Review. Acta Metall Sin, 2026, 62(1): 81-99.

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Abstract

Underwater welding technology plays a vital role in the emergency or permanent repair of underwater structures, particularly in high-end sectors such as shipping, offshore engineering, and nuclear power plants. This paper reviews the progress and challenges associated with underwater welding technology from three key perspectives: equipment development, process research, and engineering applications. Regarding equipment development, innovations such as high-performance welding power supplies, micro drainage hoods, intelligent wire feeding devices, and intelligent welding robots have significantly enhanced welding quality and efficiency. In terms of process research, the focus is on dynamic monitoring of the welding process, exploring microstructural evolution and mechanical properties, and clarifying the relationship between parameters such as heat input and microstructure. Combining these with quality optimisation methods can further enhance welding reliability and efficiency. Engineering application practices have demonstrated the significant value of underwater welding in nuclear power maintenance, ship repair, and offshore wind power restoration. Future research should drive underwater welding technology toward breakthroughs in high reliability, high efficiency, and autonomy, thereby providing critical technical support for the repair of large underwater structures.

Key words: underwater welding underwater structure welding equipment process method

Received: 15 July 2025

ZTFLH:

TG442

Fund: National Natural Science Foundation of China(U23A20625);National Natural Science Foundation of China(U2141216);National Natural Science Foundation of China(52375334);National Key Research and Development Program of China(2023YFB3407703);Natural Science Foundation of Guangdong Province(2023B1515250003)

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	Articles by authors
	WANG Zhenmin
	ZHUANG Jianpeng
	HE Zhiyu
	WANG Yuhai
	CHI Peng
	ZHANG Bin
	ZHANG Qin
	LIAO Haipeng

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https://www.ams.org.cn/EN/10.11900/0412.1961.2025.00202 OR https://www.ams.org.cn/EN/Y2026/V62/I1/81

Fig.1 1500-meter-deep pressure chamber

Fig.2 Schematics of wet underwater welding technology^[14] (S—contact area, G—gravitational force, F_L—flow drag force, α—angle between droplet and wire axis)
(a) wire and droplet under water
(b) gasflow interacting with droplet and bubble
(c) bubble rising in water around workpiece

Fig.3 Schematic of local dry welding^[15]

Fig.4 Underwater high-power fast pulse welding power supply prototype and related waveform diagrams
(a) welding power supply prototype
(b) fast pulse principle diagram (I_b—secondary current, I_m—principal current, I_D—basic current)

Fig.5 Schematics of a micro drainage hood with a double air curtain structure^[34]
(a) air inlet and sealed cap assembly
(b) overall structure of dual-air-curtain
(c) cross-sectional view of welding process

Fig.6 Schematic (a) and photograph (b) of lightweight fully sealed wire feeding device

Fig.7 Six-degree-of-freedom underwater welding robotic arm

Fig.8 Elevation welding test process of magnetic adsorption wheeled underwater welding robot^[45] (a, c) welding site photographs at spatial attitude angles of 180° (a) and 270° (c) (b, d) welding process photographs at spatial attitude angles of 180° (b) and 270° (d)

Fig.9 Wheeled humanoid welding robot prototype
(a) robot model diagram (b) robot physical photograph

Fig.10 Electrical signal analyses during partial dry underwater welding^[54] (a-e) current probability density figures and voltage-current figures (f) variation coefficients of current and voltage

Fig.11 Droplet transfer behavior at different peak pulse currents^[60] (t₀—welding commencement time)
(a) short circuit transfer process at the peak current of 240 A
(b) globular transfer process at the peak current of 260 A
(c) projected transfer process at the peak current of 280 A
(d) effect of momentum and impact force on weld penetration

Fig.12 Grain types of ferrite and austenite in weld metal at different simulated water depths^[75]
(a-h) grain structures of ferrite (a-d) and austenite (e-h) under different simulated water depths of 0.1 m (a, e), 15 m (b, f), 45 m (c, g), and 75 m (d, h) (i, j) histograms of the fraction of different grain types of the ferrite (i) and austenite (j)

Fig.13 Influence mechanism of single/double pulsed waveforms on grain growth during the local dry underwater wire arc additive manufacturing (LDU-WAAM) deposition process^[81]
(a1-a8) schematics of stirring mechanism on grain development (b1-b3, c1-c3) schematics of grain growth in each layer deposited by single pulsed waveform (SPW) (b1-b3) and double pulsed waveform (DPW) (c1-c3)

Fig.14 Weld formation and dimensions (unit: mm) at different peak currents^[60]
(a) 240 A (b) 260 A (c) 280 A (d) 300 A (e) 320 A

Fig.15 Macroscopic morphologies of welds at a water depth of 120 m^[94] (a, b) forming (a) and cross-section (b) of overlay welds (c, d) forming (a) and cross-section (b) of butt welds

Fig.16 Local dry underwater laser welded parts under different laser line energies^[98]
(a) morphology (Green cycles show the slight incomplete fusion at the edge of WM; red rectangles show the spatters and burn-through holes likely emerged)
(b) defects (c, d) effect of power (c) and speed (d) on dimensions

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