1、Fumes and Gases In the Welding Envi ron ment Fumes and Gases in the Welding Environment A Research Report on Fumes and Gases Generated During Welding Operations Research performed at Battelle-Columbus Labbratones under contract with the American Welding Society and supported by industry contribution
2、s Under the direction of the AWS RESEARCH COMMITEE ON SAFETY AND HEALTH Edited by E Y. Speight, Manager, Safety and Health, and H. C. Campbell, Consultant AMERICAN WELDING SOCIETY 2501 NW 7th Street, Miami, Horida 33125 i Reproduced By 6LOML -.- =a ENGINEERING DOCUMENTS E-F ui The Permission OF AWS
3、- Under Royahy kgmemeni Library of Congress Number: 79-51875 International Standard Book Number: 0-87171-174-5 American Welding Society, 2501 N.W. 7th Street, Miami, FL 33125 01979 by American Welding Society All rights reserved Note: By publication of this specification the American Welding Society
4、 does not insure anyone utilizing the specifica- tion against liability arising from the use of such specification. A publication of a specification by the American Welding Society does not carry with it any right to make, use, or sell any patented items. Each prospective user should make an indepen
5、dent investigation. Printed in the,United States of America Contents Personnel . vii Preface ix Supporting Organizations ContributingOrganizations !. xi Abstract . 1 Introduction: Research Program on Improving the Welding Environment 1 Overview of Fume Constituents . 1 2 Survey of Part II . Fums fro
6、m Arc We1.d ng Electrodes . 3 Survey of Part III . Fumes from Brazing 3 4 Survey of Part V . Furnes from Oxygen Cutting 4 Organization of this Report . 5 Survey of Part 1 . Fume Ventilation Data Survey of Part IV . Fumes from Thermal Spraying . Part I . Ventilation Studies . Introduction Scope . Lim
7、itations . Program . Equipment. Materiais. Procedure List of Symbols Used in Sections IA. IB. and IC . Section1A.GeneralRoomVentiiation . Fluid Dynamic Considerations . Room Ventilation Section1B.LocalVentilation . DataNeeded CalibrationofEquipment . Experimental Procedure . Experimental Results Sec
8、tion IC . Local Exhaust Studies . Calibration of Equipment ExPenmentalProc edure . ExperimentalResults . Application of Results of Part I . . Question1 . Question 2 . Summary of Part I . Question3 . 7 7 7 7 8 8 20 21 21 21 25 25 26 26 26 31 32 33 39 49 50 52 58 60 Part II . Arc Welding Fumes and Gas
9、es . 63 Introduction 63 Scope . 65 Limitations . 66 Program . 66 Equipment, Materiais, Procedure . 66 Section IIA . Laboratory Test Method . 68 procedures 68 ChmberEvaluation 68 ExpedmentalResults 69 Section IIB . Fume Generation Characteristics of Arc Welding Electrodes 70 Baseline Data . 70 Covere
10、d and Flux Cored Electrodes . 73 Solid Electrodes . 82 Section IIC . Effects of Process Variables on Fume Generation Rates 86 Current Effects i . 86 Current Density Effects . 88 Arc Voltage-Arc Length Effects . 91 Effects of Iron Powder Additions 92 Other Studies 93 Section IID . Analytical Studies
11、. 97 Analysis of Fume 97 Fume Characterization 100 Gas Detection . 100 Section IIE . Effect of Humidity on Fume Sampling . 104 Sampling Area 104 Experimental Procedures 105 Experimental Results 105 Summary of Part II 108 Principal Fumes and Gases Present 108 Covered Electrodes 109 Flux Cored Electro
12、des 109 Solid Electrodes . 110 Fume Generation Characteristics of Gas Ingsten Arc Welding 111 Processvariables 111 Other Studies . 112 AnalyticalStudies . 112 Patt III . Brazing Fumes and Gases 115 Introduction 115 Scope . 115 Limitations . 115 Program 116 Equipment. Materials. Procedure 116 Section
13、 IIIA . Total Fume Generation Characteristics 119 Flux Covered Melts 120 Gas Covered Melts . 121 Ingot Weight Losses 123 Section IIIB . Fume Composition 123 Flux Covered Melts 123 Gas Covered Melts . 123 Discussion of Analytical Data . 123 Ingot Composition and Weight Changes 126 Discussion . 126 Fi
14、ller Metai Handling and Surface Protection 127 Filler System 130 iv Test Chamber . 130 Analytical Procedures 130 Summary of Part III 130 Part Il! Thermal Spraying Fumes and Gases 131 Introduction 131 Scope . 131 Limitations . 131 Program . 132 Equipment. Materiais. Procedures 132 Section IVA . Gas C
15、ombustion Spraying 133 Discussion . 134 Section IVB . Electric Arc Spraying . 135 Discussion . 135 Summary of Part IV 136 Part V Fumes and Gases from Oxygen Cutting . 137 Introduction 137 Scope . 137 Limitations . 137 Program . 138 Equipment. Materiais. Procedures 138 Section VA . Oxyacetylene Cutti
16、ng . 139 Cutting under Normal Conditions . 139 Cutting at Various Gas Pressures 139 Cutting at Various Speeds . 139 Section VB . Oxymethane Cutting . 147 Cutting under Normal Conditions . 147 Cutting at Various Pressures . 147 Cutting at Various Speeds . 147 Discussion . 147 Fume Composition . 147 F
17、ume Particles 148 Importance of Fume Generation Rates . 148 Summary of Part V 149 Appendix A: Electrodes Used in Part II. Tables Al to A3 . 155 Appendix B: Tables BI to B43 (Tabular Data on Fume Generation Characteristics of Electrodes Used in Part II) 161 Appendix C: Tables CI to C4 (Summary of Ori
18、ginal Data. Part III) 207 Appendix D: Tables DI and 02 (Laboratory Data Sheets for Part IV) . 213 Appendix E: Tables El to E6 (Laboratory Data Sheets for Part V) 217 References and Literature Surveyed 225 Introduction. 1-6 225 PartII,2.1-2.24 . 225 PaaV. 5.1.5.2 228 PartI. 1.1-1.4 225 PartiIL3.1-3.4
19、4 Index . 229 V The authors, all employed at Battelle-Columbus Laboratories: R. M. Evans R.G. Luce L. J. Flanigan D. C. Martin D. G. Howden H. E. Pattee K. W. Lee R. E. Robinson Contributor to the experimental studies: W. H. Stefanov Edited by: E Y. Speight, American Welding Society H. C. Campbell,
20、Consultant AWS Research Committee on Safety and Health A. Lesnewich. Chairman E X Speight, Secretary R. C. Becker R. M. Gage J. F: Hinrichs (Radiation) K. L. Brown (Fumes andGases)* D. S. Janetka (Hazard Evaluation)* N C. Janes (Hazard Evaluation)* T. Kilmer (Analytical Methods) J. O. Hayden (Therma
21、l Spraying)* N B. Meyer (Thermal Spraying)* R. W Niles (Sampling Fumes and Gases)* R. L. Peaslee (Brazing)* A. W Platt E Carl Saacke (ex officio) N. B. Shankland (Noise)* I? Shaughnessy (Resktance Welding)* H. Trabbold (Ventilation)* *Consulting Member Airco Welding Products Division American Weldin
22、g Society International Harvester Company Lincoln Electric Company Union Carbide, Linde Division A. O. Smith Corporation International Harvester Company U.S. Steel Corporation Airco Welding Products Hayden Corporation St. buis Metallizing Company Eastman Kodak Company Wall Colmonoy Corporation Cater
23、pillar Tractor Company Airco, Incorporated Sciaky Brothers, Incorporated Chrysler Corporation Aircair Company Research Finance Committee C. H. Renicke, Chairman 1975-77 E.B. Scriplure, Chairman 1977- R. E. Bruggeman A. W Platt (resigned 1975) R. H. Schwegman Chemetron Corporation Teiedy ne-McKay Cat
24、erpillar Tractor Company Caterpillar Tractor Company General Electric Company vii The environment presented by welding, cutting, and similar operations is a concern to industry. Man- agement seeks to provide a safe and healthy working environment for welders, and the Occupational Safety and Health A
25、ct of 1970 has added the force of law ta this desire. Although fumes and gases associated with welding and cutting are the most obvious potential hazards, other factors-radiation, heat, and noise-must also be considered. Prior research for industry and for the American Welding Society has scarcely s
26、cratched the surface of this problem. Some work conducted has raised more questions than it has answered. Typical of these questions are the following: ( 1) Can fumes and gases be characterized on the basis of electrode classification? (2) Can simplified procedures be developed to evaluate the hazar
27、ds presented by airborne contaminants? (3) What are typical noise levels associated with welding and cutting operations? (4) How can ozone and nitrogen dioxides be detected accurately in the presence of dense fumes? (5) Are fume concentrations affected in a predictable manner by the welding variable
28、s? (6) Can the health and safety of workers be protected without affecting productivity? Reliable data are clearly needed to demonstrate that welding operations are safe when carried out properly and do not constitute an unusual occupational hazard. To help industry, AWS proposed a continuing invest
29、igation at Battelle Memorial Institute-Columbus Laboratories to study the various environments to which welders are exposed, to quanti them, to demon- strate means to cope with them in a safe manner, and to correlate laboratory and shop generated data. The processes to be studied were arc welding, o
30、xyfuel gas welding and cutting, brazing, and thermal spraying. The investigation required funding at a rate of $150,000 per year for two years. Support was obtained from industry subscriptions, and progress reports were distributed to the sponsoring companies. This report summarizes work completed t
31、o September 1978, except for studies of the noises and radia- tions generated in arc welding and cutting. A research report on the measurement of welding and cutting noise has been published separately as “Arc Welding and Cutting Noise” (Ref. i)*. Wo reports on radia- tion have been issued by the U.
32、S. Army Environmental Hygiene Agency in cooperation with the American Welding Society and Battelle-Columbus Laboratories (Refs. 2 and 3) and a brief summary has been pub- lished in the “Welding Journal” (Ref. 4). All measurements shown in the tables and text of this report are given in the system (U
33、.S. customary or S.I.) in which they were made, followed by an approximate S.I. conversion in parentheses if the me- surement was in U.S. units. No conversions are considered necessary for scientific measurements made directly in metric units. *References are grouped together following the appendix.
34、 Supporting Organizations Airco Welding Products A. O. Smith Corporation Arcair Company Arcos Corporation Armco Steel Corporation AWS Detroit Section Babcock and Wilcox Company Cabot Corporation (Stellite Division) Caterpillar Tractor Company Champion Commercial Industries, Incorporated Chemetron Co
35、rporation Combustion Engineering, Incorporated Dover Corporation (Bernard Division) Eastman Kodak Company E. I. Dupont de Nemours General Electric Company The Heil Company Hobart Brothers Company Huntington Alloys, Incorporated International Harvester Company J. I. Case Company Lincoln Electric Comp
36、any Miller Electric Company Motor Vehicle Manufacturers Association National Constructors Association National Institute for Occupational Safety and Health (NOSH) Sandvik, Incorporated Steel Plate Fabricators Association, Incorporated Stoody Company Sun Shipbuilding and Dry Dock Company Teledyne McK
37、ay The Trane Company Union Carbide Corporation, Linde Division United States Steel Victor Equipment Company WABCO Construction and Mining Group (American Standard, Incorporated) Westinghouse Electric Corporation Contri but ing Organizations Alabama Oxygen Company AWS Central Texas Section AWS Clevel
38、and Section AWS Houston Section AWS Los Angeles Section AWS New Jersey Section. AWS Philadelphia Section AWS Pittsburgh Section Bel Welding Supply Company, Incorporated Coastal Welding Supply Industriai Welding Supplies, Incorporated Iweco, Incorporated Lake Welding Supply Company Lex Company, Incor
39、porated McKenzie Repair, Incorporated Mineweld Company of Indiana, Incorporated Prest-O-Sales and Service, Incorporated Rodgers Welding Supply Company Suburban Welders Supply, Incorporated UNted Association (Alabama) In addition to the supporting and contributing organizations listed above, i19 othe
40、r organizations contributed amounts up to $500 each to the program. Ail contributions are gratefully acknowledged. xi Fumes and Gases in the Welding Environment A Research Report on Fumes and Gases Generated During Welding Operations Abstract ”he environment surrounding many welding processes contai
41、ns fumes (particulate matter) that may be harmful (toxic) or relatively hanniess and gases that may have pulmonary or non-pulmonary effects. This report sum- marizes five experimental studies and several literature surveys (conducted by Battelle Memorial Institute- Columbus Laboratories for the Amer
42、ican Welding Society) to evaluate the extent to which ventilation may control the exposure of the welder to these fumes and gases and to investigate the nature of the various fumes and gases generated in an: welding, in brazing with silver-based filler metals, in thermal spraying, and in oxyfuel gas
43、 cutting. Comprehensive fume control requires exhaust flow rates adequate to reduce room contamination below criti- cal levels, or cross-draft ventilation (or air-ventilated helmets) to remove fumes from the welders breathing zone, or sometimes both. Tables in this report show what fumes and gases a
44、re generated by fourteen types of covered electrodes for shielded metal arc welding, seven electrodes for flux cored arc welding, eleven gas metal arc solid electrodes, two BAg-class brazing filler metals, seven spraying and surfacing metals, and three thicknesses of carbon steel plate severed by ox
45、yacetylene and oxymethane cutting under various operating conditions. These data can be used in part to determine blower capacity and exhaust flow rates needed for ventilation. Introduction The American Welding Society has sponsored a two- year program, entitied “Improving the Welding Environ- ment
46、,” conducted by Battelles Columbus Laboratories. This book is a report of that research and consolidates the content of five topical reports on the program. Overview of Fume Constituents Fumes are particles formed by electrode (and base metal) constituents that are vaporized and subsequently condens
47、ed in the welding area. Because of their small size, fume particles may remain suspended in the aero- sol form for long periods. Since the particles have mass and size and are affected by air movement, electrical fields, gravity, diffusional forces, and other external forces, they tend to agglomerat
48、e into clumps that grad- ually settie on the floor and other surfaces. While sus- pended, however, they are inhaled by all persons in the vicinity. In addition to fume particles, there are also gases formed that have toxic effects. These include ozone, oxides of nitrogen, and carbon monoxide. The pr
49、esence of fumes and gases in the welding en- vironment is a matter of concern to those responsible for the well-being of welding personnel. Some constitute a potential hazard to the health of the welder while others are merely a nuisance. Potential problems can be anti- cipated by estimating the concentrations of fume and gas 1 2/FUMES AND GASES constituents in the welding area and comparing these data to established exposure standards. There are three basic ways to protect the welder from the fumes and gases generated in his or her vicinity: (1) Isolate the welder from the fumes th
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