On-the-job dangers come in many forms in the welding industry, such as environmental concerns, spatter, arc flash and welding fumes. While the first three issues cause immediate and easily recognizable problems, such as cuts, burns and gritty eyes or eyesight issues, the consequences of welding fume exposure can build up gradually and be insidious. Often, people do not realize there is even a problem until their health has already been damaged, which is why prevention is so important.
Welding fumes consist of metal particulates from the workpiece, filler metal and coatings, along with shielding gases and process gases. Different metals and gases have varying levels of toxicity. One of the most dangerous, hexavalent chromium, is produced by heating stainless steel, chromate coatings and other steels containing chromium. Fumes containing hexavalent chromium can damage the skin, eyes, nose and throat and are known to cause cancer. The tiny particles from the fumes penetrate deep into the lungs and accumulate.
Welding, soldering and brazing all produce fumes. Other thermal processes, such as plasma or laser cutting, smelting, foundry work, surface work and heat treating, can also create fumes or gas by-products. The potential dangers vary based on the type of metal and heating process, but all cause harm over time without proper protection.
Arc welding is the most widely used type of welding. Within this type of welding, flux-cored arc welding (FCAW) produces the most fumes, followed by shielded metal arc welding (SMAW), gas metal arc welding (GMAW or MIG) and gas tungsten arc welding (GTAW or TIG) in decreasing fume order.
In the United States, regulations identify acceptable exposure limits to which companies are legally obligated to adhere. However, as our understanding of health and harm deepens, those limits may not seem adequate to everyone. Taking extra precautions beyond the minimum helps ensure worker health.
The best solution is prevention. Changing careers or just not welding are not options, but good protection and fume extraction are. Employee demands and company concerns over worker health are on the rise and regulations help support health concerns. Manufacturers have also stepped up to provide new options that consider both the ergonomics and the movements that are necessary when welding.
Types of fume extraction
All extraction units work by passing contaminated air through one or more filters. Several types of extraction systems are available to fit a variety of applications. To choose the right system, the unit should use good filtration material that can be easily changed and that the way it collects fumes should fit the application.
Downdraft tables work well for collecting dust from cutting and grinding, but capturing welding fumes can be difficult. These tables work by pulling the fumes down and away from the welder’s breathing area. However, heat makes welding fumes rise, so the table has to counter the natural movement of the fumes. Capturing enough of the fumes to make the environment safe is inefficient and sometimes impossible with only this type of extraction.
Wall-mounted fume extractors can be tied into a larger filtration system and use a rigid or flexible arm positioned over the welding area. A mounted extractor frees up valuable floor space, but the arm has a limited reach. While this is not a problem for small welding jobs, on longer weld seams the arm or the project itself has to be moved to keep the extraction properly positioned for effective fume removal.
Mobile fume extractors, such as the Fronius Exento LowVac, also use a manually positioned flexible arm, but they provide freedom in shop environments that require frequent movement. Available in three-phase or single-phase power options, shop owners can decide which works best for their workspace. While the extraction arm still has to be repositioned to stay above the welding arc, the Exento has an optimized hood that needs less repositioning due to its innovative design. Mobile units like this are suitable for all types of welding and provide directional extraction to protect workers.
Source capture
Another way to provide protection is to capture welding fumes right at the source. Fume extraction torches and torch kits are usable with manual and automated GMAW and FCAW welding. Because the extraction nozzle attaches to the torch, there is no need to reposition an extraction arm during longer welds. The Fronius Exento HighVac pairs well with Exento torches. There are even kits to convert a current Fronius torch to an extraction torch with the HighVac system.
The biggest advantage to these extractors is that they catch welding fumes before they reach workers or the shop environment. One disadvantage is that the extraction nozzle is larger to capture the fumes, which can make tight areas difficult to access or reduce visibility of the weld puddle. The weight of the torch is also slightly more than a non-extraction torch. The amount of difference depends on the brand and model of the torch.
Extraction torches mitigate welding fumes at the source, protecting all workers while respirators clear the air right in front of the welder’s face. Powered air purifying respirators (PAPRs) built into the welding hood are available and work with filters worn on the body, usually on a belt. These units offer many benefits for the worker wearing them and provide more protection than a standard respirator. As with any added filtration, the weight of the welding helmet increases and the filters must be maintained for proper protection.
Understanding risks
Appropriately addressing the dangers of inhaling welding fumes cannot be overstated. By understanding the risks and implementing fume extraction solutions, companies can effectively protect their workers’ health. As regulations evolve and industry awareness grows, the commitment to exceeding safety standards becomes crucial, especially for attracting top talent.
Investing in advanced welding fume protection not only safeguards employees, but also fosters a healthier, more productive work environment, underscoring the responsibility of employers to prioritize long-term well-being over short-term compliance.
