Beneath the Waves: The Crucial Role of Gases in Underwater Welding
Beneath the Waves: The Crucial Role of Gases in Underwater Welding
Underwater welding is one of the world’s most challenging professions.
Aspiring welders require several years of training — including diving certifications — before they are allowed to work for extended periods underwater.
However, hyperbaric welding, as underwater welding is also known, is often used in the maintenance of ships or working on offshore pipelines and is thus an extremely crucial occupation.
So how does it work? And what role do gases play? Let’s take a closer look.
How does underwater welding work?
There are two types of hyperbaric welding — wet welding and dry welding.
In dry welding, the structure that is to be worked on is sealed by what is known as a hyperbaric chamber. All water is first pumped out of this chamber. The air inside is, meanwhile, maintained at a higher pressure than the water outside to ensure that the welder doesn’t get sick while working.
In some cases, welders may even create larger “habitats” for dry welding, which can accommodate two to three divers at a time. These habitats are similarly pumped with gases to maintain a breathable atmosphere for the welders.
Wet welding, on the other hand, is mostly used in emergencies or when there is no access to a hyperbaric chamber. In this case, air bubbles are released to surround an electric arc to protect the weld and reduce the electric conductivity of water.
Wet welding is very challenging as the bubbles make it harder for welders to see what they’re working on. The welds created also tend to cool rapidly, increasing the possibility of defects, while the pools are at an increased risk of contamination.
Welders must also protect themselves from shocks by wearing special diving suits and using equipment that is more heavily insulated than the average welding torch.
The Role of Gases in Underwater Welding
Gases play a crucial role in both wet and dry underwater welding.
In the case of dry welding, for instance, the hyperbaric chamber is first filled with an inert gas mixture to control the environment, thus protecting the welder and leading to improved weld quality. In most cases, this is a blend of oxygen and helium.
In the more dangerous — and slightly less effective — wet welding process, too, gases serve a purpose. Shielding gases are a must, for instance, when working with an electric arc welding rod. The air bubbles released around the arc are usually a mixture of hydrogen, carbon dioxide and carbon monoxide.
These shielding gases protect the weld area from water and oxidation. This is especially critical as if oxygen does manage to seep through, it can cause cracks in the weld.
Dive Deeper into Welding Processes with nexAir
By this point, it should be clear why underwater welding is such a high-stakes — and extremely financially rewarding — profession. Without the right KnowHow or ideal blend of gases, welds can be exposed to contaminants, and welders are placed at a higher risk of falling sick.
At nexAir, we believe the safety of welders is of paramount importance. This is why, for over 80 years, we’ve made it our mission to help industries across the Southeast Forge Forward with only the highest quality welding supplies.
nexAir in the news
Our expertise makes us more than a valuable partner, it makes us headlines
nexAir is always open!
Don't see what you're looking for?
Everything we offer is a click away and it will arrive before you know it.
Manufacturing downtime costs American companies billions annually. When production lines halt due to gas supply issues, every minute translates to lost revenue, missed deadlines, and frustrated customers. At nexAir, we've spent decades developing solutions that keep manufacturing operations running smoothly.
The Hidden Costs of Gas-Related Downtime
When manufacturers calculate downtime costs, they typically focus on labor and lost production. However, gas supply disruptions create cascading effects that multiply these losses:
- Production rescheduling that disrupts carefully optimized sequences
- Rush shipping fees to meet customer deadlines despite delays
- Quality inconsistencies when processes restart after interruptions
- Overtime costs to catch up after unplanned stoppages
- Reputation damage when delivery commitments are missed
For a typical mid-sized manufacturer, each hour of downtime represents $5,000-$10,000 in direct and indirect costs. Our analysis shows that gas-related issues cause 7-12% of total manufacturing downtime - a substantial opportunity for improvement.
From Reactive to Proactive: The Supply Continuum
Most facilities follow a predictable pattern in their gas management evolution:
Stage 1: Reactive Management At this stage, facilities order gas when they notice supplies running low or, worse, after running out. Emergencies are common, and disruptions are accepted as "part of doing business." One automotive parts supplier operating this way experienced 14 production interruptions in a single quarter.
Stage 2: Calendar-Based Management Facilities advance to scheduled deliveries based on estimated usage. While better than the reactive approach, this method still results in either excess inventory (tying up capital and space) or shortages when usage spikes occur. A plastics manufacturer following this model maintained 40% more cylinder inventory than necessary while still experiencing occasional stockouts.
Stage 3: Consumption-Based Management Our telemetry systems monitor actual gas consumption, automatically triggering orders based on usage patterns rather than calendar dates. This approach virtually eliminates both stockouts and excess inventory.
Stage 4: Integrated Supply Management The most advanced approach connects gas management directly to production planning systems. Upcoming production requirements automatically adjust supply parameters, ensuring resources are precisely aligned with needs. A medical device manufacturer using this approach reports zero gas-related downtime for 27 consecutive months while operating with minimal inventory buffers.
Our expert KnowHow™ in industrial gas applications allows us to guide customers through this evolution at a pace that makes sense for their operations.
Customizing Solutions for Maximum Uptime
Manufacturing environments vary dramatically in their gas requirements and operational constraints. We've developed flexible approaches that address these differences:
- For high-volume, consistent usage operations, our bulk systems eliminate the cylinder handling that frequently causes supply disruptions. Bulk installations include telemetry monitoring and automated ordering to prevent outages.
- For variable-demand environments, our microbulk delivery systems provide the benefits of bulk supply with lower volume commitments. These systems reduce handling requirements while maintaining the flexibility needed for changing production schedules.
- For specialized applications requiring multiple gas types, our gas management programs combine cylinder tracking, usage monitoring, and automated replenishment. This comprehensive approach ensures that specialty gases are always available when needed, regardless of how infrequently they might be used.
- For multi-site operations, our enterprise supply programs coordinate deliveries and optimize inventory across locations. By treating the organization's gas requirements holistically, we minimize both stockouts and excess inventory across the network.
This consultative approach ensures that manufacturers receive solutions aligned with their specific operational patterns rather than generic "one-size-fits-all" systems.
Beyond Traditional Supply: Integrated Services for Total Reliability
Maximum uptime requires more than just reliable gas delivery. Our integrated services address the full spectrum of gas-related reliability factors:
Equipment maintenance programs that prevent system failures before they impact production Technical gas specialists who resolve application issues that could otherwise cause production problems Safety training that prevents accidents leading to downtime events Emergency response capabilities that minimize impacts when unexpected events occur Supply chain redundancy that ensures continuity despite regional disruptions
These services complement our supply solutions to form a comprehensive reliability strategy. By addressing both everyday operations and exceptional circumstances, we help manufacturers Forge Forward with confidence that gas-related disruptions won't derail their production targets.
Measuring Success: The Results That Matter
The ultimate measure of any downtime reduction strategy is its impact on production metrics. Our manufacturing customers consistently report significant improvements after implementing our comprehensive gas management solutions:
Downtime reductions of 85-95% for gas-related issues Inventory cost decreases of 20-30% through optimized supply management Administrative time savings of 5-10 hours weekly through automated ordering and tracking Production schedule adherence improvements of 3-7% due to improved supply reliability
These performance gains translate directly to bottom-line benefits that typically deliver ROI within months rather than years. More importantly, they allow manufacturers to confidently make delivery commitments, knowing that gas supply issues won't compromise their ability to perform.
Don't let gas supply issues impact your productivity. Contact us today to explore our tailored solutions.
Looking out for your future
Get your career going on the right track with nexAir
Find out how nexAir KnowHow has impacted businesses all over the Southeast
Our expertise makes us more than a valuable partner, it makes us headlines
