See discussions, stats, and author profiles for this publication at: https://www.researchgate.

net/publication/344839452

CHEMICAL ANALYSIS OF WELDING FUME GENERATED IN SHIELDED METAL

ARC WELDING

Conference Paper · May 2006

CITATIONS READS

0 254

2 authors, including:

Sead Pasic
Dzemal Bijedic University of Mostar
62 PUBLICATIONS 9 CITATIONS

SEE PROFILE

All content following this page was uploaded by Sead Pasic on 23 October 2020.

The user has requested enhancement of the downloaded file.

 CHEMICAL ANALYSIS OF WELDING FUME
GENERATED IN SHIELDED METAL ARC WELDING

Pasic S.1, Begic R.2, Bestic D.3

ABSTRACT:

Composition of pure welding fume elements can be harmful to worker's health if inhaled or swallowed.
That's why the welding fume composition has to be tested for toxicity. Welders are exposed to these
elements if they inhale the welding fume, consisted of metal oxide particles formed by welding. These
particles are small enough to stay in the air and easy to inhale. In welding with covered electrodes,
fume is made of the cover particles such as: Fe, Mn, F, Zn, Ni, Cu, Cr, Mo, Co, Pb etc. This paper
analyses chemical composition of welding fume generated by use of ,,ELVACO“ covered electrodes
Bijeljina. Acquired results were compared to the testing made on similar electrodes types by various
European and American producers.

KEY WORDS

Welding fume, Chemical analysis, Toxicity, Covered electrodes

AUTHOR DETAILS
1
“Dzemal Bijedic“ University, Faculty of Mechanical Engineering, Mostar, Bosnia & Herzegovina
2
University of Bihac, Technical Faculty, Bihac, Bosnia & Herzegovina
3
“ELVACO“ A.D., Arc Welding Electrodes, Bijeljina, Bosnia & Herzegovina
1. INTRODUCTION

Arc welding is the most common type of welding used for production of structural steel, but as well in
welding of non-iron materials and their alloys. Welded joints in arc welding are made by melting of
base material, mostly with usage of certain filler material. Electrodes used in welding can be meltable
(serve as filler materials) or unmeltable. In arc welding, metal is melted by the heat of the electric arc
that is generated between the workpiece and the electrode. In welding with covered electrodes,
electric arc temperature can be as high as 6700 ◦C, depending on welding parameters, chemical
composition of electrode material, cover thickness etc. High welding temperatures result in burning
down of certain elements from base and filler material. Burnt material in the form of welding fume rises
to the atmosphere in the form of polluters with very harmful impact to the welder's health. Welding
fumes are toxic metal fumes generated in all procedures of arc welding. Chemical composition of the
gases is different and depends on the composition of base and filler welding material, electrode cover,
as well as on the applied welding process type. Welding fume consists of gasses and metal oxide
particles formed during welding. The number, size and composition of the particles in the welding
fume is a significant factor for estimate of pollution level and harmness to the welders' health.

SMAW procedure with covered electrodes is one of the welding processes in which the emission of
welding fume is noticeable, due, among other, to the fume generated from the electrode cover. Type
and thickness of electrode plays a very important role in the welding process: it decreases ionization
potential in the welding arc length which enables easier ignition and more stable arc, better protection
of melted metal and acts as blast furnace slag. The electrode cover serves several purposes: alloy
elements Mn, Ni, Cr, Mo are added to the electrode cover, and thus it performs alloyage. Additionally,
the electrode cover is to remove extra oxygen and hydrogen from the melted material, in other words it
performs de-aeration, and finally it is to remove sulfur and phosphorus from the melt, i.e. to refine it.
All this generally improves mechanical properties of the welded joint. During the welding process, a
considerable amount of fume is generated that then protect the welding pool from bad effects from
atmosphere. However, along with the positive influence on welding, electrodes cover evidently
generate a considerable amount of welding fume that pollutes environment and unfavorably effects
working conditions. This paper analyses amount and composition of welding fume generated in
welding of certain types of basic and rutile electrodes made by a home producer of electrodes, „Elvaco
AD“ Bijeljina.

2. WELDING FUME

Welding fume as a product of arc welding is an unavoidable chemical and physical emission into
environment. The composition of such an emission will depend on both chemical content of the
welded alloys and conditions under which the reaction happens. Primary components are metal
oxides produced by joining of metal elements, elements from electrode cover and oxygen, at a high
arc temperature. During a welding process, there is a possibility of pollution of atmosphere from other
sources, such as the protective layer, including Zn and Cd, paint or oil traces, etc. Welding fumes
have a typical smell and their specific composition vary considerably. In German regulations on the
accident prevention, these substances are stated as „substances harmful to health“ and treated
accordingly. Bad influences have to be estimated so that proper measures can be undertaken on
protection of welder's health. [1]. Welding fumes contain a high level of harmful substances so it is
necessary to evaluate damages caused bad chemical effects. In indoor space, welding can be very
harmful to the welder's health. Without good ventilation, effects of poisonous gases and fumes can be
even stronger. The most important components, from toxicological point of view, are given in the Table
1.

2
 Table 1 – Harmful metals and metal oxides and their effects to human health [2]

Metal Causing factors Potential effects

Soluble Cr-VI: irritative and toxic effects on skin and
Hexa valence
mucous membrane.
Cr compounds
Insoluble Cr-VI: cancerogenous for humans (lungs,
(chromium, Cr -VI)
respiratory tract), allergic skin effects.
Compounds with
Carcinogenic for humans (lungs, nostrils), allergic skin
Ni low and high
effects
solubility, NiO
Metal and Harmful to nerves, as oxide it is irritative and toxic to
Mn
compounds respiratory tract, neurotoxic.
Causes mental fiver including respiratory arrest
Oxide - fume
Zn (incomprehensible mechanism, possible immunological
constituent
one), generally unexplained damages.
Causes mental fiver including respiratory arrest
Oxide – fume
Cu (incomprehensible mechanism, possible immunological
constituent
one), generally unexplained damages.
Chronicle bronchitis, asthma (possibly toxic and/or
Metal and allergic), in hard metals causes pulmonary fibrosis,
Co
compounds cancerogenous in experiments on animals, allergic skin
effects.
Toxic for kidneys (long-lasting poisoning effects), as an
Metal and
Cd oxide it has a toxic effect on respiratory tract and lungs,
compounds
cancerogenous in experiments on animals.
Metal and inorganic
Pb Anemia, harmful to nerves and kidneys.
compounds
Metal and As dust causes pulmonary fibrosis, possible harmful to
Al
compounds nerves.
Soluble in
Ba Harmful to nerves and muscles, affects salt balance.
compounds

2.1. Classification, chemical composition

With respect to the results acquired from the studies on harmful substances in welding and based on
effects of these substances on human health, a procedure has been proposed that includes the
following factors for evaluation of damaging effect: process factors, effect factors and working place
factors. Both process and effect factors take into consideration emission level (mg/s) on the one hand,
and effects of these gases and particles on the other. Particles, as opposed to gases, appear in
almost all process – material combinations and problem of their presence is complex due to their
quantity and composition. With regard to the particle emission level (mg/s), welding processes can be
divided in 4 levels, as shown in the Table 2.

Table 2 – Particle emission level [1]

No. Level Particle emission level [mg/s] Welding procedure

1. Level 1 low emission < 1 mg/s GTAW
2. Level 2 middle emission level 1÷2 mg/s Laser welding
3. Level 3 high emission level >2÷25 mg/s SMAW, GMAW
4. Level 4 very high emission level >25 mg/s Specific welding conditions

3
The Table 2 shows that the fume emission level in SMAW high and thus it is necessary to apply
required measures for protection of welders. Table 3 shows appearance of key components in SMAW,
caused by welding of various base materials: size of the space, airiness and position of head and
body of welders can be taken as relevant for working place.

Table 3 – Key components in welding fume in SMAW procedure [1]

Welding
Base material Key components
procedure
Fumes generated in welding of such materials
Unalloyed or low-alloy steel with
have upper level of content harmful to
< 5% of alloy elements
respiratory tract
SMAW Mild steel with < 20% of Cr Cr -VI – hexa valence chromium and other
and < 30% of Ni components
NiO – Nickel oxide and CuO – copper oxide,
Ni, Ni alloys > 30% of Ni
possibly for alloys of nickel and copper

3. ANALYSIS OF FUME CHEMICAL COMPOSITION

Welding fume emission, its quantity and composition depend on a various number of factors. Still, all
these factors can be grouped into the three main groups: welding type influence, base material
influence and filler material influence. Welding procedure influence and influence of base material on
fume emission have been shown through examples of research taken from relevant literature, while
for testing of filler material influence on fume emission, results of the author’s own research on
various types of covered electrodes were used.

Results of a research conducted in France were used as an illustration of welding type influence on
the type and quantity of welding fume [3]. Chemical composition of welding fume in manual arc
welding of stainless steel is shown in the Table 4. Also, the Table shows chemical composition of
welding fume for several different welding procedures, and values of generated harmful substances
can be compared. It is evident that the welding procedures SMAW and FCAW generate the most of
fume, and that their composition is unfavorable, especially regarding its very dangerous,
cancerogenous, hexa valency chromium CrVI.

Table 4 – Welding fume composition for various welding procedures [3]

Chemical composition of welding fume G [%]

Welding
Shielding gas Cr Cr
process Fe Mn Si Ca K Na F Mg Ni
VI total
0.2- 0.2- 1- 1- 0.1-
SMAW - 5-20 1-12
13 10 25 15 20
-- 0.1-6 0.5-6 1-10

Ar+
GMAW 30-40 1-12 1-4 -- -- -- -- -- 2-8 0.2-1 8-13
2%O2
Ar+ 10-20 4-8 2-8 0.1-5 1-3
5-
3-6 -- 1-3 0.3-2 8-13
25%CO2 12
FCAW
0.01-
Self-protection 13 6 4 1 18 5 21
3
3 4 9
SAW Self-protection -- -- -- -- -- -- -- -- <1.0 <0.1 2

Influence of base material on welding fume emission is shown on basis of some American research
[4]. Low-alloy steels were used: A-36, HY-100 i HSLA-100. Welding was performed using manual arc
procedure, SMAW, with the covered electrode E11018-M used as filler material. Very wide application

4
of these steels, primarily in shipbuilding industry, caused intense research on welding emission fumes,
with special attention paid to the influence of hexa valence chromium CrVI on fuming during welding of
the abovementioned materials. Steel marked as HY-100 contains 1.0-1.8% of Cr, HSLA-100 contains
0.45-0.75% of Cr, while A-36 doesn't contain chromium. Testing was performed on steel plates of 12.5
do 19,0 mm of thickness, and chemical analysis of the welding fume is shown in the table 5.

Table 5 – Chemical composition of welding fume in SMAW procedure [4]

Base
A - 36 HY - 100 HSLA - 100
material
Electrode HY 11018 - M HY 11018 - M HY 11018 - M
Chemical composition of welding fume [%]
CrVI <0.1 <0.1 <0.1
Al 0.3 0.2 0.3
Ti 1.0 1.1 1.1
Si 2.8 3.0 2.9
Fe 20.3 18.3 18.2
Ca 13.8 14.1 14.4
Mn 7.5 7.3 7.6
K 7.2 7.9 7.7
Ba <0.2 <0.2 <0.2
Ni <0.2 <0.2 <0.2
Cr <0.2 <0.2 <0.2
Mo <0.2 <0.2 <0.2
Nb <0.2 <0.2 <0.2
V <0.2 <0.2 <0.2
Cu <0.2 <0.2 <0.2
Na 8.9 9.1 9.1
Li <0.2 <0.2 <0.2
P 18.1 20.9 19.2

For testing of influence of generated welding fume and its composition, two types of covered
electrodes made by „ELVACO AD“ Bijeljina company were used: the rutile electrode EL E 13 R and
the basic electrode EL E 61 B. Chemical composition and mechanical properties of pure metal at the
welded joint for the used electrodes are shown in the table 6.

Type EL E 13 R is applied for welding in shipbuilding, production or machinery, car industry and other
welding works. It is particularly suitable in production of fillet welds and welded butt joints. In welding, it
gives stable arc and easy slag removal.

Type EL E 61 B is a basic-covered hydrogen controlled electrode designed for all-positional welding,

except vertically down, of carbon and medium tensile steels and mild steels under the conditions of
high restrain. Striking and re-striking qualities are good and the slag is easily removed. It is used for all
general fabrication where hydrogen control is required.

Welding fume emission was tested on the total of 10 electrodes, 5 of each of the two types, of various
diameter and welding current. In testing of the electrode EL E 27 R, electrodes of standard diameters,
Ø 2.0 up to Ø 5.0 mm were used, with welding current of 55 up to 200 A, while EL E 61 B electrodes
were of standard diameters from Ø 2.5 to Ø 6.0 mm, with welding current 80 up to 300 A. Chemical
analysis of welding fume samples of all tested covered electrodes was done in the laboratories of
,,Liverpool Regional Office“ UK, and the results were shown in the tables 7 and 8.

5
 Table 6 – Chemical composition and mechanical properties
of the covered electrodes EL E 13 R i EL E 61 B [5]

Standard
Electrode Chemical composition Mechanical characteristics
designation
type of welded metal % max. of welded metal
according to
EN 499/95 C 0,080 Rm [N/mm2] 430-510
E 35 2 R 12 Mn 0,440 ReH [N/mm2] 412-490
AWS A5.1/91 Si 0,100 A5 [%] > 24
EL E 13 R
E 6013 S 0,022 +20OC 105
DIN 1913/84 P 0,028 KV [J] 0 OC 93
E 43 33 R 3 -20 OC 86
2
EN 499/95 C 0,070 Rm [N/mm ] 510-610
E 42 4 B 32 H 5 Mn 0,800 ReH [N/mm2] 450-500
AWS A5.1/91 Si 0,500 A5 [%] > 24
EL E 61 B
E 7018 S 0,020 +20OC 200
DIN 1913/84 P 0,020 KV [J] 0 OC 150
E 5153 B 12 -20 OC 100

Table 7 – Results of the analysis of welding fume for the electrode EL E 27 R [6]

Analysis of chemical composition of welding fume

of the covered electrode ELVACO EL E 27 R
EL E 27R
Electrode type
(E 32 R 12 in accordance with EN 499/95)
Electrode diameter Ø [mm] 2.0 2.5 3.25 4 5
Welding current [A] 55 70 110 160 200
Fume emission G [mg/s] 1,4 1,4 1,4 2,8 2,8
Fume class 1 1 1 1 2

Total fume limit value

3.5 3.5 3.5 3.5 3.5
HGV INDEX [mg/m3]

Nominal hygienic level in air

1160 1220 1480 2700 3150
NHL [m3/h]
Analysis of chemical composition of welding fume [%]
Fe 5.4 5.4 5.5 5.6 5.5
Mn 6.2 6.3 6.4 6.2 6.5
F - - - - -
Zn 0.009 0.009 0.010 0.012 0.012
Ni 0.002 0.002 0.002 0.002 0.002
Cu 0.044 0.044 0.044 0.041 0.044
Cr 0.06 0.05 0.06 0.07 0.07
Mo 0.001 0.001 0.001 0.001 0.001
Co - - - - -
Pb 0.002 0.002 0.002 0.002 0.002

6
 Table 8 – Results of analysis of welding fume for the electrode EL E 61 B [6]

Analysis of chemical composition of welding fume

of the covered electrode ELVACO EL E 61 B
EL E 61 B (E 42 4 B 32 H 5, in accordance with
Electrode type
EN 499/95)
Electrode diameter Ø [mm] 2.5 3.2 4 5 6
Welding current [A] 80 110 160 200 300
Fume emission G [mg/s] 4,2 5,6 8,3 8,3 11,1
Fume class 2 2 3 3 3

Total fume limit value

3.5 3.5 3.5 3.5 3.5
HGV INDEX [mg/m3]

Nominal hygienic level for air

4300 5800 8680 9250 11570
NHL [m3/h]
Analysis of chemical composition of welding fume [%]
Fe 3.4 3.4 3.4 3.4 3.4
Mn 4.8 4.8 4.8 4.8 4.8
F 16.2 16.2 16.2 16.2 16.2
Zn 0.01 0.01 0.01 0.01 0.01
Ni 0.02 0.02 0.02 0.02 0.02
Cu 0.03 0.03 0.03 0.03 0.03
Cr 0.02 0.02 0.02 0.02 0.02
Mo 0.01 0.01 0.01 0.01 0.01
Co - - - - -
Pb 0.01 0.01 0.01 0.01 0.01

Having analyzed acquired results it can be concluded that welding fume emission ranges within usual
limits: in rutile electrode EL E 13 R, total fume emission is from 1,4 mg/s for an electrode with Ø 2,0
mm diameter and the welding current of 55 A, up to 2,8 mg/s for an electrode of a Ø 5,0 mm diameter
and the welding current of 200 A, while in the basic electrode EL E 61 B, these values are slightly
higher and range from 4,2 mg/s for an electrode of a Ø 2,5 mm diameter and the welding current of 80
A, up to 11,1 mg/s for an electrode of a Ø 6,0 mm diameter and the welding current of 300 A, Figure 1.
In both cases, composition of the welding fume and quantity of its harmful elements are within allowed
limits and thus don't represent a threat to welder's health.

7
 electrode diameter  mm
2,0 2,5 3,25 4,0 5,0 6,0
12

10

fume emission mg/s

8

6 electrode EL E 13 R
electrode EL E 61 B

50 100 150 200 250 300

welding current A

Figure 1 – Dependence of welding fume emission on electrode current and diameter

4. CONCLUSION

SMAW is one of the procedures with a high-level fume emission, ranked as 3 from total of 4 levels.
According to this, fumes generated in SMAW are potentially dangerous. Metals in welding fume are
mainly generated in the form of oxides, and more than 90% of the fume comes from the electrode.
Base material has relatively small influence on the fume composition, except for the metals that
contain covers made of Zn, Cd or nonferrous metals. Composition and quantity of the fumes depend
on the process variable: electrode type, polarity, arc voltage and the current. Electrode cover can be a
fuming source, in combination with metal oxides that it generates. Fume concentration in the welding
zone can go beyond allowed limit of 5 mg/m3 and some sort of control is usually required. Although
safety measures are usually well set in the SMAW, still working environment needs to be permanently
improved in order to lower potential dangers to the welders. Special emphasis is put on reducing of
fumes containing oxides Ni, Mn and CrIV.

Further research in SMAW could possibly be directed toward development of electrodes whose fume
would contain less harmful substances. Such a process, of course, mustn't affect arc stability or
welded joint quality. If it is needed to add metals of high-level toxicity to the electrode wire, then it's
better to do additional alloyage of the electrode wire. This alternative is better that adding of a metal
powder in the electrode covering, since alloyage produces less fuming from the allyoed electrode.

5. REFERENCES

[1] V.-E. SPIEGEL-CIOBANU: Evaluation of health hazards caused by hazardous substances in

welding, ASR International Conference -2003-Bucharest.
[2] Welding Fumes and Gases, CPWR, NIOSH, 2003.
[3] P.JEAN CUNAT, Chromium in Stainless Steel Welding Fumes, International Chromium
Development Association, N 0 9 – April, France, 2002.
[4] H. CASTNER and C.L. NULL, Chromium, Nickel and Manganese in Shipyard Welding Fumes,
Edison Welding Institute, Ohio, U.S. Navy, Naval Sea Systems Command, Arlington, 1998.
[5] ,,ELVACO” Bijeljina, Katalog dodatnih materijala za zavarivanje, 2005.
[6] Technical report covered electrodes welding fumes, Liverpool Regional Office, UK. 2003.

View publication stats