Characterizing particle emissions from a direct energy deposition additive manufacturing process and associated occupational exposure to airborne particles

Assessment of nanoparticle emission in additive manufacturing: Comparing wire and powder laser metal deposition processes

Additive manufacturing (AM), often referred to as 3D printing, is an emerging technology with a wide range of industrial applications and process typologies. Although the release of metal nanoparticles as by-products could occur, occupational exposure limits and cogent safety standards are not currently available due to the novelty of the technology. To support the definition of benchmarks, this study aims to provide a preliminary comparison between the nanoparticle release patterns of laser metal deposition, adopting different feedstocks, namely, metal wire and metal powder. The monitored device is a university research setup, and the work presents the results of two different processes with AISI 316 L as a feedstock in powder and wired form, respectively. The monitoring confirmed the outcomes of previous studies, with a high release of nanoparticles from the powder head on the device (average 138,713 n/cm3 during printing, with maximum values exceeding 106 n/cm3). Moreover, the results show a significant concentration of nanoparticles with a wire head during the printing phase (average release of 628,156 n/cm3 with a maximum of 1,114,987 n/cm3) and pauses (average of 32,633 n/cm3 and a maximum of 733,779 n/cm3). The monitored values during pauses are particularly relevant since no personal protection equipment was used in the wire processes and the operators could access the printing room during pauses for device interventions, thus being exposed to significant nanoparticle concentrations. This study presents a preliminary evaluation of the potential exposure during laser metal deposition while implementing different technologies and provides evidence for defining effective operational safety procedures for the operators.

Emissions and Exposures Associated with the Use of an Inconel Powder during Directed Energy Deposition Additive Manufacturing

Additive manufacturing (AM) has been linked to potential exposure-related health risks, however, there is a paucity of sufficient research. This study aimed to supply information regarding emissions and exposure during directed energy deposition (DED) AM using inconel 718, with the main constituents being nickel, chromium, and cobalt. By using standardized occupational hygiene methods, the measurement strategy consisted of a combined approach, including powder characterization, particle emission monitoring, and personal exposure monitoring of AM operators. Powder characterization of virgin and used powder indicated no significant difference in particle size, shape, or elemental composition. Particle number emissions ranged between 102 and 105 p/cm3 for submicron particles (<1 µm in size). There was no significant difference in the particle emission rate between the three phases of AM or the two types of DED machines (p > 0.05). The particle emission rate for submicron particles peaked at 2.8 × 109 p/min. Metals of concern to human health were detected during the AM process but were considerably lower than the relevant exposure limits. This study confirms particle emissions, predominantly in the submicron range, above the background concentration during DED AM and, although insignificant in terms of potential health effects, AM operators are exposed to detectable concentrations of the metal constituents of inconel.

Direct-reading instruments for aerosols: A review for occupational health and safety professionals part 2: Applications

Direct reading instruments (DRIs) for aerosols have been used in industrial hygiene practice for many years, but their potential has not been fully realized by many occupational health and safety professionals. Although some DRIs quantify other metrics, this article will primarily focus on DRIs that measure aerosol number, size, or mass. This review addresses three applications of aerosol DRIs that occupational health and safety professionals can use to discern, characterize, and document exposure conditions and resolve aerosol-related problems in the workplace. The most common application of aerosol DRIs is the evaluation of engineering controls. Examples are provided for many types of workplaces and situations including construction, agriculture, mining, conventional manufacturing, advanced manufacturing (nanoparticle technology and additive manufacturing), and non-industrial sites. Aerosol DRIs can help identify the effectiveness of existing controls and, as needed, develop new strategies to reduce potential aerosol exposures. Aerosol concentration mapping (ACM) using DRI data can focus attention on emission sources in the workplace spatially illustrate the effectiveness of controls and constructively convey concerns to management and workers. Examples and good practices of ACM are included. Video Exposure Monitoring (VEM) is another useful technique in which video photography is synced with the concentration output of an aerosol DRI. This combination allows the occupational health and safety professional to see what tasks, environmental situations, and/or worker actions contribute to aerosol concentration and potential exposure. VEM can help identify factors responsible for temporal variations in concentration. VEM can assist with training, engage workers, convince managers about necessary remedial actions, and provide for continuous improvement of the workplace environment. Although using DRIs for control evaluation, ACM and VEM can be time-consuming, the resulting information can provide useful data to prompt needed action by employers and employees. Other barriers to adoption include privacy and security issues in some worksites. This review seeks to provide information so occupational health and safety professionals can better understand and effectively use these powerful applications of aerosol DRIs.

Comprehensive Analysis of Two H13-Type Starting Materials Used for Laser Cladding and Aerosol Particles Formed in This Process

Laser cladding with H13 steel powders was performed and the related material transformations were studied for the particles emitted during this process. Fractions of various sizes of the aerosol particles formed during the laser cladding were collected on a cascade impactor, while the electromobility and the aerodynamic size of the particles were measured using a scanning mobility particle spectrometer and an aerodynamic particle sizer, respectively. The aerosol particles deposited onto the impactor plates were analyzed using scanning electron microscopy−energy-dispersive X-ray spectroscopy, as well as total-reflection X-ray fluorescence and X-ray absorption near-edge structure spectroscopy. Both the concentration and mean oxidation state of the major components were correlated with the aerosol particle size. The ultrafine aerosol particles (with a diameter less than about 100 nm) were predominantly oxidized and formed as the result of an evaporation−oxidation−condensation process sequence. The larger particles (>200 nm in geometric diameter) were primarily the residues of the original metal powder and exhibited a composition change as compared to the as-received metal powder. Correlations between the changes in the concentration ratio of the components were detected and explained.

Characterisation of Particles Emitted during Laser Cutting of Various Metal Sheets and an Exposure Assessment for the Laser Operators

Laser cutting is used in many industrial settings to achieve precise cuts of metal sheets. Laser operators may be exposed to particles formed during cutting when opening the cabinet or when metal sheets are exchanged. To characterise the potential exposure, particles formed during laser cutting were studied with scanning electron microscopy equipped with an energy dispersive X-ray detector and an energy backscatter diffraction detector. The total concentration of particles (11-615 nm) was determined online with a scanning mobility particle sizer. The chemical composition of the particles formed during the cutting of the different metal sheets was determined by inductively coupled plasma mass spectrometry (ICP-MS). X-ray diffraction was applied to determine the phase composition. The occupational exposure was assessed gravimetrically and by ICP-MS for five laser operators handling different laser cutters, and materials and were found to be low. Agglomerates and aggregates of condensation particles were formed during laser cutting, independent of the sheet type. Iron, present as both magnetite and α-Fe, was the main element found in the particles formed when cutting steel sheets. The size of the particles generated was mainly below 300 nm. Open laser cutters may lead to higher metal exposures, which is especially relevant when cutting metal sheets containing heavy metals.

Identification of effective control technologies for additive manufacturing

Additive manufacturing (AM) refers to several types of processes that join materials to build objects, often layer-by-layer, from a computer-aided design file. Many AM processes release potentially hazardous particles and gases during printing and associated tasks. There is limited understanding of the efficacy of controls including elimination, substitution, administrative, and personal protective technologies to reduce or remove emissions, which is an impediment to implementation of risk mitigation strategies. The Medline, Embase, Environmental Science Collection, CINAHL, Scopus, and Web of Science databases and other resources were used to identify 42 articles that met the inclusion criteria for this review. Key findings were as follows: 1) engineering controls for material extrusion-type fused filament fabrication (FFF) 3-D printers and material jetting printers that included local exhaust ventilation generally exhibited higher efficacy to decrease particle and gas levels compared with isolation alone, and 2) engineering controls for particle emissions from FFF 3-D printers displayed higher efficacy for ultrafine particles compared with fine particles and in test chambers compared with real-world settings. Critical knowledge gaps identified included a need for data: 1) on efficacy of controls for all AM process types, 2) better understanding approaches to control particles over a range of sizes and gas-phase emissions, 3) obtained using a standardized collection approach to facilitate inter-comparison of study results, 4) approaches that go beyond the inhalation exposure pathway to include controls to minimize dermal exposures, and 5) to evaluate not just the engineering tier, but also the prevention-through-design and other tiers of the hierarchy of controls.

Towards sustainable additive manufacturing: The need for awareness of particle and vapor releases during polymer recycling, making filament, and fused filament fabrication 3-D printing

Fused filament fabrication three-dimensional (FFF 3-D) printing is thought to be environmentally sustainable; however, significant amounts of waste can be generated from this technology. One way to improve its sustainability is via distributed recycling of plastics in homes, schools, and libraries to create feedstock filament for printing. Risks from exposures incurred during recycling and reuse of plastics has not been incorporated into life cycle assessments. This study characterized contaminant releases from virgin (unextruded) and recycled plastics from filament production through FFF 3-D printing. Waste polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) plastics were recycled to create filament; virgin PLA, ABS, high and low density polyethylenes, high impact polystyrene, and polypropylene pellets were also extruded into filament. The release of particles and chemicals into school classrooms was evaluated using standard industrial hygiene methodologies. All tasks released particles that contained hazardous metals (e.g., manganese) and with size capable of depositing in the gas exchange region of the lung, i.e., granulation of waste PLA and ABS (667 to 714 nm) and filament making (608 to 711 nm) and FFF 3-D printing (616 to 731 nm) with waste and virgin plastics. All tasks released vapors, including respiratory irritants and potential carcinogens (benzene and formaldehyde), mucus membrane irritants (acetone, xylenes, ethylbenzene, and methyl methacrylate), and asthmagens (styrene, multiple carbonyl compounds). These data are useful for incorporating risks of exposure to hazardous contaminants in future life cycle evaluations to demonstrate the sustainability and circular economy potential of FFF 3-D printing in distributed spaces.

State of the art in additive manufacturing and its possible chemical and particle hazards-review

Additive manufacturing, enabling rapid prototyping and so-called on-demand production, has become a common method of creating parts or whole devices. On a 3D printer, real objects are produced layer by layer, thus creating extraordinary possibilities as to the number of applications for this type of devices. The opportunities offered by this technique seem to be pushing new boundaries when it comes to both the use of 3D printing in practice and new materials from which the 3D objects can be printed. However, the question arises whether, at the same time, this solution is safe enough to be used without limitations, wherever and by everyone. According to the scientific reports, three-dimensional printing can pose a threat to the user, not only in terms of physical or mechanical hazards, but also through the potential emissions of chemical substances and fine particles. Thus, the presented publication collects information on the additive manufacturing, different techniques, and ways of printing with application of diverse raw materials. It presents an overview of the last 5 years' publications focusing on 3D printing, especially regarding the potential chemical and particle emission resulting from the use of such printers in both the working environment and private spaces.

Additive Manufacturing for Occupational Hygiene: A Comprehensive Review of Processes, Emissions, & Exposures

This comprehensive review introduces occupational (industrial) hygienists and toxicologists to the seven basic additive manufacturing (AM) process categories. Forty-six articles were identified that reported real-world measurements for all AM processes, except sheet lamination. Particles released from powder bed fusion (PBF), material jetting (MJ), material extrusion (ME), and directed energy deposition (DED) processes exhibited nanoscale to submicron scale; real-time particle number (mobility sizers, condensation nuclei counters, miniDiSC, electrical diffusion batteries) and surface area monitors (diffusion chargers) were generally sufficient for these processes. Binder jetting (BJ) machines released particles up to 8.5 µm; optical particle sizers (number) and laser scattering photometers (mass) were sufficient for this process. PBF and DED processes (powdered metallic feedstocks) released particles that contained respiratory irritants (chromium, molybdenum), central nervous system toxicants (manganese), and carcinogens (nickel). All process categories, except those that use metallic feedstocks, released organic gases, including (but not limited to), respiratory irritants (toluene, xylenes), asthmagens (methyl methacrylate, styrene), and carcinogens (benzene, formaldehyde, acetaldehyde). Real-time photoionization detectors for total volatile organics provided useful information for processes that utilize polymer feedstock materials. More research is needed to understand 1) facility-, machine-, and feedstock-related factors that influence emissions and exposures, 2) dermal exposure and biological burden, and 3) task-based exposures. Harmonized emissions monitoring and exposure assessment approaches are needed to facilitate inter-comparison of study results. Improved understanding of AM process emissions and exposures is needed for hygienists to ensure appropriate health and safety conditions for workers and for toxicologists to design experimental protocols that accurately mimic real-world exposure conditions.ABBREVIATIONS ABS : acrylonitrile butadiene styrene; ACGIH® TLV® : American Conference of Governmental Industrial Hygienists Threshold Limit Value; ACH : air change per hour; AM : additive manufacturing; ASA : acrylonitrile styrene acrylate; AVP : acetone vapor polishing; BJ : binder jetting; CAM-LEM : computer-aided manufacturing of laminated engineering materials; CNF : carbon nanofiber; CNT : carbon nanotube; CP : co-polyester; CNC : condensation nuclei counter; CVP : chloroform vapor polishing; DED : directed energy deposition; DLP : digital light processing; EBM : electron beam melting; EELS : electron energy loss spectrometry; EDB : electrical diffusion batteries; EDX : energy dispersive x-ray analyzer; ER : emission rate; FDM™ : fused deposition modeling; FFF : fused filament fabrication; IAQ : indoor air quality; LSP : laser scattering photometer; LCD : liquid crystal display; LDSA : lung deposited particle surface area; LOD : limit of detection; LOM : laminated object manufacturing; LOQ : limit of quantitation; MCE : mixed cellulose ester filter; ME : material extrusion; MJ : material jetting; OEL : occupational exposure limit; OPS : optical particle sizer; PBF : powder bed fusion; PBZ : personal breathing zone; PC : polycarbonate; PEEK : poly ether ether ketone; PET : polyethylene terephthalate; PETG : Polyethylene terephthalate glycol; PID : photoionization detector; PLA : polylactic acid; PM1 : particulate matter with aerodynamic diameter less than 1 µm; PM2.5 : particulate matter with aerodynamic diameter less than 2.5 µm; PM10 : particulate matter with aerodynamic diameter less than 10 µm; PSL : plastic sheet lamination; PVA : polyvinyl alcohol; REL : recommended exposure limit; SDL : selective deposition lamination; SDS : safety data sheet; SEM : scanning electron microscopy; SL : sheet lamination; SLA : stereolithography; SLM : selective laser melting; SMPS : scanning mobility particle sizer; SVOC : semi-volatile organic compound; TEM : transmission electron microscopy; TGA : thermal gravimetric analysis; TPU : thermo polyurethane; UAM : ultrasonic additive manufacturing; UC : ultrasonic consolidation; TVOC : total volatile organic compounds; TWA : time-weighted average; VOC : volatile organic compound; VP : vat photopolymerization.

Occupational exposure during metal additive manufacturing: A case study of laser powder bed fusion of aluminum alloy

Occupational exposure during metal additive manufacturing (Laser Powder Bed Fusion) using an aluminum alloy (AlSi10Mg) was assessed. Background aerosols before manufacturing, powder sieving, machine loading, manufacturing, machine unloading, powder unpacking, and machine cleaning were analyzed. Measurements were taken simultaneously at the source, in the near field, and on the operator during five manufacturing cycles. Aerosol measurement devices and physico-chemical techniques were used to determine the particle number or mass concentration (DiSCmini, core particle counter and sampling cassette), particle size distribution (NanoScan, optical particle detector and impactor), and the shape/size and chemical compositions of the inhalable particles (laser diffraction, inductively coupled plasma spectroscopy, scanning electron microscopy, energy dispersive X-ray microanalysis, and Brunauer-Emmett-Teller Method). The laser powder-bed fusion machine emitted in the additive manufacturing room an inhalable fraction of 2.37 ± 0.35 mg/m3, with an aerosol number concentration ranging from 2 × 104 to 105 #/cm3 and a mass mean aerodynamic diameter of 318 nm. A relatively low concentration level was observed in the near field of the machine with an aerosol number concentration of ∼104 #/cm3. A higher concentration level on the operator was attained during the unpacking and cleaning steps, showing an inhalable fraction of 1.73 ± 0.30 mg/m3. Al and Mg nanoparticles were aerosolized at the source (inside the laser powder-bed fusion machine) with a particle size distribution of 153 nm for Al and 117 nm for Mg and an aerosol number concentration reaching ten times that of the background aerosol level. The number or mass concentration of particles in the room atmosphere was increased to double that of the background aerosol level at specific workstations during manufacturing. Metal additive manufacturing is a source of potential occupational exposure to airborne metal nanoparticles. Particle-counting instruments showed high numbers of nanoparticles and some important peaks of particles ranging from 10 nm to 10 µm or larger at specific work tasks in the Additive Manufacturing (AM) environment. A multimetric approach was used to characterize the particle emissions resulting from this type of additive manufacturing.

Nano-remediation of toxic heavy metal contamination: Hexavalent chromium [Cr(VI)]

The inexorable industrialization and modern agricultural practices to meet the needs of the increasing population have polluted the environment with toxic heavy metals such as Cr(VI), Cu²⁺, Cd²⁺, Pb^2+, and Zn²⁺. Among the hazardous heavy metal(loid)s contamination in agricultural soil, water, and air, hexavalent chromium [Cr(VI)] is the most virulent carcinogen. The metallurgic industries, tanneries, paint manufacturing, petroleum refineries are among various such human activities that discharge Cr(VI) into the environment. Various methods have been employed to reduce the concentration of Cr(VI) contamination with nano and bioremediation being the recent advancement to achieve recovery at low cost and higher efficiency. Bioremediation is the process of using biological sources such as plant extracts, microorganisms, and algae to reduce the heavy metals while the nano-remediation uses nanoparticles to adsorb heavy metals. In this review, we discuss the various activities that liberate Cr(VI). We then discuss the various conventional, nano-remediation, and bioremediation methods to keep Cr(VI) concentration in check and further discuss their efficiencies. We also discuss the mechanism of nano-remediation techniques for better insight into the process.

A review on recent trends of antiviral nanoparticles and airborne filters: special insight on COVID-19 virus

Novel corona virus (COVID-19) pandemic in the last 4 months stimulates the international scientific community to search for vaccine of antiviral agents suitable for in activating the virus inside and outside the human body. More than 4 million people globally are infected by the virus and about 300,000 dead cases until this moment. The ventilation and airborne filters are also investigated aiming to develop an efficient antiviral filtration technology. Human secretion of the infected person as nasal or saliva droplets goes as airborne and distributes the virus everywhere around the person. N95 and N98 filters are the must use filters for capturing particles of sizes around 300 nm. The average size of the novel corona virus (COVID-19) is 100 nm and there is no standard or special filter suitable for this virus. The nanoparticle-coated airborne filter is a suitable technique in this regard. While the efficiency of this type of filters still needs to be enhanced, new developed nanofiber filters are proposed. Most recently, the charged nanofiber filters of sizes below 100 nm are developed and provide an efficient viral filtration and inactivation. The efficiency of filter must be kept at accepted level without increasing the pressure drop. The present review outlines the most efficient antiviral nanoparticles including the recent functional nanoparticles. The filtration theory, filtration modeling, filter testing, and different types of filter with special concentration on the charged nanofiber filter were discussed. The charged nanofiber filter able to capture novel corona virus (COVID-19) with 94% efficiency and a pressure drop less than 20 MPa.

Phosphate Buffer Solubility and Oxidative Potential of Single Metals or Multielement Particles of Welding Fumes

To evaluate the chemical behavior and the health impact of welding fumes (WF), a complex and heterogeneous mixture of particulate metal oxides, two certified reference materials (CRMs) were tested: mild steel WF (MSWF-1) and stainless steel WF (SSWF-1). We determined their total chemical composition, their solubility, and their oxidative potential in a phosphate buffer (PB) solution under physiological conditions (pH 7.4 and 37 °C). The oxidative potential (OPDTT) of WF CRMs was evaluated using an acellular method by following the dithiothreitol (DTT) consumption rate (µmol DTT L−1 min−1). Pure metal salts present in the PB soluble fraction of the WF CRMs were tested individually at equivalent molarity to estimate their specific contribution to the total OPDTT. The metal composition of MSWF-1 consisted mainly of Fe, Zn, Mn, and Cu and the SSWF-1 composition consisted mainly of Fe, Mn, Cr, Ni, Cu, and Zn, in diminishing order. The metal PB solubility decreased from Cu (11%) to Fe (approximately 0.2%) for MSWF-1 and from Mn (9%) to Fe (<1%) for SSWF-1. The total OPDTT of SSWF-1 is 2.2 times the OPDTT of MSWF-1 due to the difference in oxidative capacity of soluble transition metals. Cu (II) and Mn (II) are the most sensitive towards DTT while Cr (VI), Fe (III), and Zn (II) are barely reactive, even at higher concentrations. The OPDTT measured for both WF CRMs extracts compare well with simulated extracts containing the main metals at their respective PB-soluble concentrations. The most soluble transition metals in the simulated extract, Mn (II) and Cu (II), were the main contributors to OPDTT in WF CRMs extracts. Mn (II), Cu (II), and Ni (II) might enhance the DTT oxidation by a redox catalytic reaction. However, summing the main individual soluble metal DTT response induces a large overestimation probably linked to modifications in the speciation of various metals when mixed. The complexation of metals with different ligands present in solution and the interaction between metals in the PB-soluble fraction are important phenomena that can influence OPDTT depletion and therefore the potential health effect of inhaled WF.