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<p>Underwater wet DC welding of Fe 410 steel offers a practical and cost-effective method for in situ repair and fabrication in submerged environments. This technique can be applied for the repair of offshore structures, ship building and marine repair, hydropower and port infrastructure, and underwater construction works. This study focuses on the formulation and testing of waterproof-coated electrodes designed to withstand the hostile underwater conditions. Key welding parameters including the type of electrode, current, and electrode diameter were systematically optimized using statistical design of experiments to minimize defects and enhance mechanical properties. The optimal combination of parameters for maximizing tensile strength was electrode type A, an electrode diameter of 3.0&#xa0;mm, and a current setting around 200 A. The optimal parameter combination for maximizing Charpy strength was electrode type A, a current around 200 A, and an electrode diameter of 2.5&#xa0;mm, ensuring a balance of toughness and process stability. Electrode type A, a higher current, and an electrode diameter of 3.0&#xa0;mm were identified as optimal settings for achieving maximum hardness. Confirmation tests were performed for the same. The findings confirm that electrode A possesses better results than the other two electrodes. Optical microscopy and SEM analysis were performed for the welded zone prepared through electrode A.</p>

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Development and Parameter Optimization of Electrodes to Enhance Mechanical Properties in Underwater Wet Direct Current Welding of Fe 410 Steel

  • 期刊论文

  • 发表日期：

    2025年11月26日

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  • Achman Mishra,
  • Manish Maurya,
  • Shailendra Singh Chauhan,
  • Nagendra Kumar Maurya,
  • Ram Jatan Yadav,
  • Manish Giri

摘要

Underwater wet DC welding of Fe 410 steel offers a practical and cost-effective method for in situ repair and fabrication in submerged environments. This technique can be applied for the repair of offshore structures, ship building and marine repair, hydropower and port infrastructure, and underwater construction works. This study focuses on the formulation and testing of waterproof-coated electrodes designed to withstand the hostile underwater conditions. Key welding parameters including the type of electrode, current, and electrode diameter were systematically optimized using statistical design of experiments to minimize defects and enhance mechanical properties. The optimal combination of parameters for maximizing tensile strength was electrode type A, an electrode diameter of 3.0 mm, and a current setting around 200 A. The optimal parameter combination for maximizing Charpy strength was electrode type A, a current around 200 A, and an electrode diameter of 2.5 mm, ensuring a balance of toughness and process stability. Electrode type A, a higher current, and an electrode diameter of 3.0 mm were identified as optimal settings for achieving maximum hardness. Confirmation tests were performed for the same. The findings confirm that electrode A possesses better results than the other two electrodes. Optical microscopy and SEM analysis were performed for the welded zone prepared through electrode A.