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Antonini JM, Kodali V, Meighan TG, McKinney W, Cumpston JL, Leonard HD, Cumpston JB, Friend S, Leonard SS, Andrews R, Zeidler-Erdely PC, Erdely A, Lee EG, Afshari AA. Lung toxicity, deposition, and clearance of thermal spray coating particles with different metal profiles after inhalation in rats. Nanotoxicology 2023; 17:669-686. [PMID: 38116948 PMCID: PMC10872229 DOI: 10.1080/17435390.2023.2297048] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/28/2023] [Accepted: 12/12/2023] [Indexed: 12/21/2023]
Abstract
Thermal spray coating is a process in which molten metal is sprayed onto a surface. Little is known about the health effects associated with these aerosols. Sprague-Dawley rats were exposed to aerosols (25 mg/m3 × 4 hr/d × 4 d) generated during thermal spray coating using different consumables [i.e. stainless-steel wire (PMET731), Ni-based wire (PMET885), Zn-based wire (PMET540)]. Control animals received air. Bronchoalveolar lavage was performed at 4 and 30 d post-exposure to assess lung toxicity. The particles were chain-like agglomerates and similar in size (310-378 nm). Inhalation of PMET885 aerosol caused a significant increase in lung injury and inflammation at both time points. Inhalation of PMET540 aerosol caused a slight but significant increase in lung toxicity at 4 but not 30 d. Exposure to PMET731 aerosol had no effect on lung toxicity. Overall, the lung responses were in the order: PMET885≫PMET540 >PMT731. Following a shorter exposure (25 mg/m3 × 4 h/d × 1d), lung burdens of metals from the different aerosols were determined by ICP-AES at 0, 1, 4 and 30 d post-exposure. Zn was cleared from the lungs at the fastest rate with complete clearance by 4 d post-exposure. Ni, Cr, and Mn had similar rates of clearance as nearly half of the deposited metal was cleared by 4 d. A small but significant percentage of each of these metals persisted in the lungs at 30 d. The pulmonary clearance of Fe was difficult to assess because of inherently high levels of Fe in control lungs.
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Affiliation(s)
- James M Antonini
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Vamsi Kodali
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Terence G Meighan
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Walter McKinney
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Jared L Cumpston
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Howard D Leonard
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - James B Cumpston
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Sherri Friend
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Stephen S Leonard
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Ronnee Andrews
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Patti C Zeidler-Erdely
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Aaron Erdely
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Eun Gyung Lee
- Respiratory Health Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
| | - Aliakbar A Afshari
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, USA
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Kodali V, Afshari A, Meighan T, McKinney W, Mazumder MHH, Majumder N, Cumpston JL, Leonard HD, Cumpston JB, Friend S, Leonard SS, Erdely A, Zeidler-Erdely PC, Hussain S, Lee EG, Antonini JM. In vivo and in vitro toxicity of a stainless-steel aerosol generated during thermal spray coating. Arch Toxicol 2022; 96:3201-3217. [PMID: 35984461 DOI: 10.1007/s00204-022-03362-7] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.5] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 05/25/2022] [Accepted: 08/11/2022] [Indexed: 11/26/2022]
Abstract
Thermal spray coating is an industrial process in which molten metal is sprayed at high velocity onto a surface as a protective coating. An automated electric arc wire thermal spray coating aerosol generator and inhalation exposure system was developed to simulate an occupational exposure and, using this system, male Sprague-Dawley rats were exposed to stainless steel PMET720 aerosols at 25 mg/m3 × 4 h/day × 9 day. Lung injury, inflammation, and cytokine alteration were determined. Resolution was assessed by evaluating these parameters at 1, 7, 14 and 28 d after exposure. The aerosols generated were also collected and characterized. Macrophages were exposed in vitro over a wide dose range (0-200 µg/ml) to determine cytotoxicity and to screen for known mechanisms of toxicity. Welding fumes were used as comparative particulate controls. In vivo lung damage, inflammation and alteration in cytokines were observed 1 day post exposure and this response resolved by day 7. Alveolar macrophages retained the particulates even after 28 day post-exposure. In line with the pulmonary toxicity findings, in vitro cytotoxicity and membrane damage in macrophages were observed only at the higher doses. Electron paramagnetic resonance showed in an acellular environment the particulate generated free radicals and a dose-dependent increase in intracellular oxidative stress and NF-kB/AP-1 activity was observed. PMET720 particles were internalized via clathrin and caveolar mediated endocytosis as well as actin-dependent pinocytosis/phagocytosis. The results suggest that compared to stainless steel welding fumes, the PMET 720 aerosols were not as overtly toxic, and the animals recovered from the acute pulmonary injury by 7 days.
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Affiliation(s)
- Vamsi Kodali
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA.
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA.
| | - Aliakbar Afshari
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Terence Meighan
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Walter McKinney
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Md Habibul Hasan Mazumder
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Center for Inhalation Toxicology (iTOX), School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Department of Pharmaceutical Sciences, School of Pharmacy, West Virginia University, Morgantown, WV, 26506, USA
| | - Nairrita Majumder
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Center for Inhalation Toxicology (iTOX), School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
| | - Jared L Cumpston
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Howard D Leonard
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - James B Cumpston
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Sherri Friend
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
| | - Stephen S Leonard
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
- Department of Pharmaceutical Sciences, School of Pharmacy, West Virginia University, Morgantown, WV, 26506, USA
| | - Aaron Erdely
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Center for Inhalation Toxicology (iTOX), School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
| | - Patti C Zeidler-Erdely
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Center for Inhalation Toxicology (iTOX), School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
| | - Salik Hussain
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
- Center for Inhalation Toxicology (iTOX), School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
| | - Eun Gyung Lee
- Respiratory Health Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26505, USA
| | - James M Antonini
- Centers for Disease Control and Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, USA
- Department of Physiology and Pharmacology, School of Medicine, West Virginia University, Morgantown, WV, 26506, USA
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Afshari AA, McKinney W, Cumpston JL, Leonard HD, Cumpston JB, Meighan TG, Jackson M, Friend S, Kodali V, Lee EG, Antonini JM. Development of a thermal spray coating aerosol generator and inhalation exposure system. Toxicol Rep 2022; 9:126-135. [PMID: 35127456 PMCID: PMC8810300 DOI: 10.1016/j.toxrep.2022.01.004] [Citation(s) in RCA: 2] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 11/23/2021] [Revised: 01/10/2022] [Accepted: 01/21/2022] [Indexed: 11/28/2022] Open
Abstract
An automated thermal spray coating generator and inhalation exposure system was designed and developed. The system can generate a consistent concentration of particles during thermal spray coating for an extended period. The aerosols were complex metal oxides and arranged as chain-like agglomerates. A short-term exposure study indicated that thermal spray coating stainless-steel aerosols significantly increased lung toxicity. With the development of this thermal spray coating system, dose-response animal toxicology studies can be performed.
Thermal spray coating involves spraying a product (oftentimes metal) that is melted by extremely high temperatures and then applied under pressure onto a surface. Large amounts of a complex metal aerosol (e.g., Fe, Cr, Ni, Zn) are formed during the process, presenting a potentially serious risk to the operator. Information about the health effects associated with exposure to these aerosols is lacking. Even less is known about the chemical and physical properties of these aerosols. The goal was to develop and test an automated thermal spray coating aerosol generator and inhalation exposure system that would simulate workplace exposures. An electric arc wire-thermal spray coating aerosol generator and exposure system was designed and separated into two areas: (1) an enclosed room where the spray coating occurs; (2) an exposure chamber with different measurement devices and controllers. The physicochemical properties of aerosols generated during electric arc wire-thermal spray coating using five different consumable wires were examined. The metal composition of each was determined by inductively coupled plasma-atomic emission spectroscopy (ICP-AES), including two stainless-steel wires [PMET720 (82 % Fe, 13 % Cr); PMET731(66 % Fe, 26 % Cr)], two Ni-based wires [PMET876 (55 % Ni, 17 % Cr); PMET885 (97 % Ni)], and one Zn-based wire [PMET540 (99 % Zn)]. The particles generated regardless of composition were poorly soluble, complex metal oxides and mostly arranged as chain-like agglomerates and similar in size distribution as determined by micro-orifice uniform deposit impactor (MOUDI) and electrical low-pressure impactor (ELPI). To allow for continuous, sequential spray coating during a 4-hr exposure period, a motor rotated the metal pipe to be coated in a circular and up-and-down direction. In a pilot animal study, male Sprague-Dawley rats were exposed to aerosols (25 mg/m3 × 4 h/d × 9 d) generated from electric arc wire- thermal spray coating using the stainless-steel PMET720 consumable wire. The targeted exposure chamber concentration was achieved and maintained during a 4-hr period. At 1 d after exposure, lung injury and inflammation were significantly elevated in the group exposed to the thermal spray coating aerosol compared to the air control group. The system was designed and constructed for future animal exposure studies to generate continuous metal spray coating aerosols at a targeted concentration for extended periods of time without interruption.
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Affiliation(s)
- Aliakbar A. Afshari
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Walter McKinney
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Jared L. Cumpston
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Howard D. Leonard
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - James B. Cumpston
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Terence G. Meighan
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Mark Jackson
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Sherri Friend
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Vamsi Kodali
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - Eun Gyung Lee
- Respiratory Health Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
| | - James M. Antonini
- Health Effects Laboratory Division, National Institute for Occupational Safety and Health, Morgantown, WV, 26508, United States
- Corresponding author at: Centers for Disease Control & Prevention, National Institute for Occupational Safety and Health, Health Effects Laboratory Division, 1000 Frederick Lane (Mailstop 2015), Morgantown, WV, 26508, United States.
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