Toxic Fumes in Welding: What Every Welder Needs to Know

Common Welding Processes and Their Fume Risks

Different welding techniques generate specific fumes depending on the materials being welded. Below is an overview of some of the most common processes and the toxic fumes you may encounter

 MIG Welding Fume Risks

• MIG Welding with Steel: When welding mild steel or carbon steel, the fumes primarily consist of iron oxide, along with small amounts of other elements that may be present in the steel alloy, such as manganese and silicon. These elements can cause respiratory issues with prolonged exposure.
• MIG Welding with Galvanized Steel: If the base metal is galvanized (coated with zinc), the welding process will vaporize the zinc, producing toxic zinc oxide fumes. This is one of the most common sources of hazardous fumes in MIG welding, leading to “metal fume fever,” a flu-like condition with symptoms such as chills, fever, and muscle aches.
• MIG Welding with Aluminium: If you’re using aluminium wire for MIG welding, the heat of the welding process can release aluminium oxide fumes. These fumes are generally less toxic than others but can still cause respiratory irritation with prolonged exposure.
• MIG Welding with Stainless Steel: If you’re welding stainless steel, the fumes can contain elements like chromium and nickel, both of which can pose significant health risks, especially hexavalent chromium, which is carcinogenic. Prolonged exposure to chromium and nickel fumes can lead to severe respiratory conditions and lung cancer.
• Hard facing Alloys (for MIG): Hard facing often involves alloys containing chromium, nickel, or cobalt. Fumes from these alloys are highly toxic and require strict ventilation and PPE measures.

 TIG Welding Fume Risks

• TIG Welding with Steel and Stainless Steel: TIG welding of steel and stainless steel involves high temperatures that release fumes containing chromium, nickel, and iron oxides. The fumes from welding stainless steel are particularly dangerous due to the presence of hexavalent chromium, a known carcinogen. Long-term exposure to these fumes can cause serious respiratory issues, including lung cancer.
• TIG Welding with Aluminium: When welding aluminium with TIG, the process produces aluminium oxide fumes. Although these fumes are less toxic than those from other materials, they can still irritate the respiratory system with prolonged exposure. This is especially true in poorly ventilated areas.

• TIG Welding with Titanium:
  TIG welding titanium emits titanium dioxide fumes. Prolonged exposure can irritate the lungs and lead to potential chronic respiratory issues.
• TIG Welding with Copper:
  Welding copper produces copper oxide fumes, which can cause “metal fume fever.” Symptoms include chills, fever, and nausea, often felt shortly after exposure.
• TIG Welding with Tungsten:
  Tungsten is generally stable, but TIG electrodes (often containing thorium) can release radioactive particles during grinding. These particles are hazardous when inhaled.

MMA Welding Fume Risks

• MMA Welding with Steel: MMA welding with mild steel produces fumes mainly consisting of iron oxide. These are relatively less toxic but can cause irritation in the lungs when inhaled in high concentrations.
• MMA Welding with Galvanized Steel: Similar to MIG, MMA welding with galvanized steel releases toxic zinc oxide fumes. These fumes can cause metal fume fever and other respiratory issues.
• MMA Welding with Stainless Steel: MMA welding of stainless steel generates toxic fumes that contain chromium, nickel, and other alloying elements. These fumes are hazardous and can cause long-term health issues such as lung cancer, especially from prolonged exposure to hexavalent chromium.
• MMA Flux Fumes: Flux combustion during MMA welding releases fine particulates, fluoride compounds, silicates, and gases such as carbon monoxide and nitrogen oxides. These fumes can cause acute respiratory irritation, eye and throat discomfort, and, with prolonged exposure, may lead to chronic lung conditions like pneumoconiosis. Ensure proper ventilation, use respiratory protection, and avoid welding in confined spaces without fume extraction.

Sources of Toxic Fumes in Welding

During the welding process, intense heat causes metals and their coatings to vaporize, releasing potentially hazardous fumes. Common toxic substances released during welding include:

• Lead: Found in certain alloys and coatings, lead exposure can lead to poisoning and neurological damage.
• Cadmium: Present in galvanized steel, cadmium fumes are extremely toxic and can cause severe respiratory and kidney damage.
• Chromium: A component of stainless steel, chromium fumes, particularly hexavalent chromium, are carcinogenic and pose severe health risks.
• Nickel: Commonly used in stainless steel alloys, nickel exposure can lead to long-term respiratory issues.
• Zinc: Found in galvanized steel, zinc fumes can cause “metal fume fever,” characterized by flu-like symptoms.

Each welding process can release specific types of fumes based on the materials used. For example, welding galvanized steel can lead to zinc fume exposure, while welding stainless steel may expose you to chromium and nickel fumes.

Health Risks of Welding Fumes

Exposure to welding fumes can have varying health effects, depending on the metal being welded and the level of exposure. Below is a breakdown of what it feels like when exposed to each toxic fume.

Lead Fumes

• Short-term Exposure: Headaches, nausea, dizziness, fatigue, and throat irritation.
• Long-term Exposure: Memory loss, cognitive dysfunction, irritability, high blood pressure, kidney damage, and neurological problems.

Cadmium Fumes

• Short-term Exposure: Severe lung damage, coughing, chest pain, difficulty breathing, fever, and metallic taste in the mouth.
• Long-term Exposure: Chronic lung diseases, kidney damage, lung cancer, and bone disease.

Chromium Fumes (Hexavalent Chromium)

• • Short-term Exposure: Respiratory irritation, coughing, wheezing, nosebleeds, and difficulty breathing.
  • Long-term Exposure: Chronic respiratory conditions, lung cancer, skin ulcers, and other cancers.

Nickel Fumes

• • Short-term Exposure: Coughing, wheezing, sore throat, and shortness of breath.
  • Long-term Exposure: Chronic bronchitis, emphysema, lung cancer, and skin sensitization.

Zinc Fumes (from Galvanized Steel)

• • Short-term Exposure: “Metal fume fever,” which includes symptoms like fever, chills, muscle aches, cough, and headaches. Symptoms are typically temporary but can be intense.
  • Long-term Exposure: Chronic respiratory issues, coughing, and lung irritation.

Safety Measures to Prevent Exposure

To minimize the risks it is crucial to take proactive safety measures. These steps will help protect yourself and your team from harmful exposure:

Minimizing the risks requires the right safety measures and equipment. Implement these strategies to protect yourself and your team:

• • Proper Ventilation: Ensure the workspace is well-ventilated with natural airflow or mechanical systems. Ventilation helps disperse hazardous fumes and prevents buildup in enclosed spaces.
  • Personal Protective Equipment (PPE): Always wear suitable PPE, including welding helmets with air filtration, respirators, gloves, and protective clothing. For example, 3M Adflo Systems offer advanced respiratory protection, filtering out harmful particles and fumes.
  • Fume Extraction Systems: Use dedicated fume extraction systems, such as the Kemper ProfiMaster or other portable and fixed units, to capture and remove fumes at the source. These devices, including fume extractor fans and local exhaust ventilation (LEV) setups, are essential for maintaining clean air in the workspace.
  • Regular Training: Train all team members to recognize the risks of welding fumes and to use safety equipment effectively. Regular training ensures everyone stays informed about best practices and is prepared to respond to hazards.

References:

Health and Safety Executive (HSE) – Welding fume: Protect Your Workers

The HSE provides comprehensive guidelines on the risks of welding fumes and the necessary safety precautions.

Welding Fumes – Health and Safety Executive (HSE)

British Occupational Hygiene Society (BOHS) – Breathe Freely in Manufacturing

The Breathe Freely in Manufacturing campaign focuses on improving respiratory health protection for welders and tackling the dangers of welding fumes.

Welding Fumes – British Occupational Hygiene Society (BOHS)

Institute of Occupational Medicine (IOM) – Welding Fume Research
The IOM provides research and findings on the dangers of welding fumes and the effects on long-term health.

Welding Fume Studies – Institute of Occupational Medicine (IOM)

Health, Safety, and Welding Fume Assessment – TWI
TWI provides expert guidance on assessing welding fume exposure and implementing effective safety measures to protect workers’ health.

Welding Fume Assessment – TWI

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