Control of exposure to hexavalent chromium and ozone in gas metal arc welding of stainless steels by use of a secondary shield gas

Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes

Background Cr(VI) is a suspected human carcinogen formed as a by-product of stainless steel welding. Nano-alumina and nano-titania coating of electrodes reduced the welding fume levels. Objective To investigate the effect of nano-coating of welding electrodes on Cr(VI) formation rate (Cr(VI) FR) from a shielded metal arc welding process. Methods The core welding wires were coated with nano-alumina and nano-titania using the sol-gel dip coating technique. Bead-on plate welds were deposited on SS 316 LN plates kept inside a fume test chamber. Cr(VI) analysis was done using an atomic absorption spectrometer (AAS). Results A reduction of 40% and 76%, respectively, in the Cr(VI) FR was observed from nano-alumina and nano-titania coated electrodes. Increase in the fume level decreased the Cr(VI) FR. Discussion Increase in fume levels blocked the UV radiation responsible for the formation of ozone thereby preventing the formation of Cr(VI).

Double shroud delivery of silica precursor for reducing hexavalent chromium in welding fume

The welding process yields a high concentration of nanoparticles loaded with hexavalent chromium (Cr(6+)), a known human carcinogen. Previous studies have demonstrated that using tetramethylsilane (TMS) as a shielding gas additive can significantly reduce the Cr(6+) concentration in welding fume particles. In this study, a novel insulated double shroud torch (IDST) was developed to further improve the reduction of airborne Cr(6+) concentration by separating the flows of the primary shielding gas and the TMS carrier gas. Welding fumes were collected from a welding chamber in the laboratory and from a fixed location near the welding arc in a welding facility. The Cr(6+) content was analyzed with ion chromatography and X-ray photoelectron spectroscopy (XPS). Results from the chamber sampling demonstrated that the addition of 3.2 ≈ 5.1% of TMS carrier gas to the primary shielding gas resulted in more than a 90% reduction of airborne Cr(6+) under all shielding gas flow rates. The XPS result confirmed complete elimination of Cr(6+) inside the amorphous silica shell. Adding 100 ≈ 1000 ppm of nitric oxide or carbon monoxide to the shielding gas could also reduce Cr(6+) concentrations up to 57% and 35%, respectively; however, these reducing agents created potential hazards from the release of unreacted agents. Results of the field test showed that the addition of 1.6% of TMS carrier gas to the primary shielding gas reduced Cr(6+) concentration to the limitation of detection (1.1 μg/m(3)). In a worst-case scenario, if TMS vapor leaked into the environment without decomposition and ventilation, the estimated TMS concentration in the condition of field sampling would be a maximum 5.7 ppm, still well below its flammability limit (1%). Based on a previously developed cost model, the use of TMS increases the general cost by 3.8%. No visual deterioration of weld quality caused by TMS was found, although further mechanical testing is necessary.

Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive

Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 μg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium.