Welding Fume Particles Research Articles

Elemental composition of particles formed during welding with stick electrodes

The elemental composition of welding fume (WF) respirable particles formed in carbon and low-alloy steels welding with stick electrodes with rutile (ANO-4) and the basic (UONI 13/45) type of coating was studied by X-ray-spectral electron-probe microanalysis. In the range from 0.25 to 16 µm aerodynamic diameter, all WF particles were divided into three groups according to their iron content: low (Fe≤20%), medium (20%<Fe<40%) and high (Fe≥40%). Each group contains various amounts of elements originating from the welding materials, which reflects their formation mechanism. Their relative abundance in WF depends on the particles aerodynamic diameter, type of electrode coating and the arc power. Particles with the medium iron content (agglomerates of nanosized primary particles) formed the largest group (over 70%) of respirable WF particles. For each electrode type, their average elemental composition does not depend on the size of the agglomerates. The low iron particles contain various combinations of electrode coating elements, and the variety of combinations increases with their aerodynamic diameter grows.These WF particles can be identified as aggregates of primary particles agglomerates and microspatters formed by disintegration of the electrode coating. WF particles with a high iron content are formed by aggregation of molten electrode metal microdroplets and nanosized primary particles agglomerates. They mainly contain iron (60–70%)and oxygen (15–35%). Their average elemental composition does not depend on the size of the aggregates, type of electrode coating and the arc power. The obtained results can be useful for the analysis and assessment of health risks for welders.

Numerical simulation of the collection efficiency of welding fume particles in electrostatic precipitator

Numerical simulation of the collection efficiency of welding fume particles in electrostatic precipitator

Study on mass concentration and morphology of SMAW fume particles with a new covered electrode using nano-CaTiO3 as an arc stabilizer

Advances in manufacturing emphasize on the development of sustainable and green manufacturing processes. Welding is a popular manufacturing process practiced worldwide. The paper presented here describes a new covered electrode for a shielded metal arc welding (SMAW) process wherein nano-sized calcium titanate (CaTiO3) powder was used as an arc stabilizer, replacing the conventional micro sized CaTiO3 in the flux. The effect of this flux modification on the mass concentration and morphology of welding fume particulates was systematically investigated. The mass concentration of coarse, fine and sub-micron sized fume particulates was measured by segregating the fumes in a four-stage personal cascade impactor. The particle mass distribution was estimated from the mass median aerodynamic diameter (MMAD) and geometric standard deviation (GSD) of the fume particulates. The morphology of fumes at each impactor stage was analysed using scanning electron microscopy and its count median diameter (CMD) was determined. The results indicated as much as 48 % reduction in total fumes and 54 % reduction in the breathing zone concentration of fumes when the entire CaTiO3 in the electrode flux was substituted with nano-CaTiO3. Morphological analysis indicated that a large fraction of the fumes from the conventional electrode were polydispersed particles, while the new electrodes predominantly contained monodispersed particles which have a relatively faster rate of removal from the lungs. Overall, the present work indicated that introducing nano sized CaTiO3 as an arc stabilizer to the flux covering of SMAW electrode could not only reduce the hazardous fume emissions but also reduce its biological activity and toxicity, thus making the process more sustainable and environment friendly.

Welding Fume Instillation in Isolated Perfused Mouse Lungs-Effects of Zinc- and Copper-Containing Welding Fumes.

Zinc- and copper-containing welding fumes can cause systemic inflammation after exposure in humans. Recent ex vivo studies have shown that the observed inflammation originates from exposed immune cells. In vitro studies identified the soluble fraction of metal particles as the main effectors. Isolated perfused mouse lungs (IPLs) were perfused and ventilated for 270 min. Lungs were instilled with saline solution (control), welding fume particle suspension (WFs) or the soluble fraction of the welding fumes (SF-WFs). Bronchoalveolar lavage fluid (BALF) and perfusate samples were analyzed for cytokine levels and lung tissue mRNA expression levels were analyzed via RT-PCR. All lungs instilled with WFs did not complete the experiments due to a fatal reduction in tidal volume. Accordingly, IL-6 and MPO levels were significantly higher in BALF of WF lungs compared to the control. IL-6 and MPO mRNA expression levels were also increased for WFs. Lungs instilled with SF-WFs only showed mild reactions in tidal volume, with BALF and mRNA expression levels not significantly differing from the control. Zinc- and copper-containing welding fume particles adversely affect IPLs when instilled, as evidenced by the fatal loss in tidal volume and increased cytokine expression and secretion. The effects are mainly caused by the particles, not by the soluble fraction.

Modelled lung deposition and retention of welding fume particles in occupational scenarios: a comparison to doses used in vitro

Translating particle dose from in vitro systems to relevant human exposure remains a major challenge for the use of in vitro studies in assessing occupational hazard and risk of particle exposure. This study aimed to model the lung deposition and retention of welding fume particles following occupational scenarios and subsequently compare the lung doses to those used in vitro. We reviewed published welding fume concentrations and size distributions to identify input values simulating real-life exposure scenarios in the multiple path particle dosimetry (MPPD) model. The majority of the particles were reported to be below 0.1 μm and mass concentrations ranged between 0.05 and 45 mg/m3. Following 6-h exposure to 5 mg/m3 with a count median diameter of 50 nm, the tracheobronchial lung dose (0.89 µg/cm2) was found to exceed the in vitro cytotoxic cell dose (0.125 µg/cm2) previously assessed by us in human bronchial epithelial cells (HBEC-3kt). However, the tracheobronchial retention decreased rapidly when no exposure occurred, in contrast to the alveolar retention which builds-up over time and exceeded the in vitro cytotoxic cell dose after 1.5 working week. After 1 year, the tracheobronchial and alveolar retention was estimated to be 1.15 and 2.85 µg/cm2, respectively. Exposure to low-end aerosol concentrations resulted in alveolar retention comparable to cytotoxic in vitro dose in HBEC-3kt after 15–20 years of welding. This study demonstrates the potential of combining real-life exposure data with particle deposition modelling to improve the understanding of in vitro concentrations in the context of human occupational exposure.

Measurement of welding fume production in welding with high-alloy electrodes

Due to their good structural properties, stainless Cr-Ni steels have a very wide application in various branches of technology. During the welding of stainless Cr-Ni steels with high-alloy coated electrodes, welding fumes of complex chemical composition are generated, which is very harmful for welders and the environment. For the purposes of this experiment, two variants of one rutile Cr-Ni commercial electrode, designated E 23 12 2 LR 12, were designed and fabricated. Higher production of welding fume particles also means greater danger to humans and the environment. In order to show the influence of the base material on the production of welding fume particles, an experiment for measuring the production of welding fume particles was performed in which two different steels were used as the base material, general structural steel S235JRG2 and stainless steel X6CrNiTi18.10.

Investigation of the influence of electrode manufacturers ‘recipes on the production and chemical composition of welding fume particles

The quality of the welded joint, production and chemical composition of welding fume particles in the MMAW process, in addition to the welding parameters, mostly depend on the quality of the coated electrode. As part of the preliminary experimental research of the optimal technological composition of the electrode coating, from the aspect of minimizing welding fume, an experimental research of one class of electrodes, E 42 4 B 32 H5, EN 499/94, standard production program of three manufacturers of welding consumables. The test was performed to examine the influence of the manufacturer’s recipe on the production and chemical composition of welding fume particles.

Genotoxicity and inflammatory potential of stainless steel welding fume particles - an in vitro study on standard vs Cr(VI)-reduced flux-cored wires and the role of released metals

Welders are daily exposed to various levels of welding fumes containing several metals. This exposure can lead to an increased risk for different health effects which serves as a driving force to develop new methods that generate less toxic fumes. The aim of this study was to explore the role of released metals for welding particle-induced toxicity and to test the hypothesis that a reduction of Cr(VI) in welding fumes results in less toxicity by comparing the welding fume particles of optimized Cr(VI)-reduced flux-cored wires (FCWs) to standard FCWs. The welding particles were thoroughly characterized, and toxicity (cell viability, DNA damage and inflammation) was assessed following exposure to welding particles as well as their released metal fraction using cultured human bronchial epithelial cells (HBEC-3kt, 5–100 µg/mL) and human monocyte-derived macrophages (THP-1, 10–50 µg/mL). The results showed that all Cr was released as Cr(VI) for welding particles generated using standard FCWs whereas only minor levels (< 3% of total Cr) were released from the newly developed FCWs. Furthermore, the new FCWs were considerably less cytotoxic and did not cause any DNA damage in the doses tested. For the standard FCWs, the Cr(VI) released in cell media seemed to explain a large part of the cytotoxicity and DNA damage. In contrast, all particles caused rather similar inflammatory effects suggesting different underlying mechanisms. Taken together, this study suggests a potential benefit of substituting standard FCWs with Cr(VI)-reduced wires to achieve less toxic welding fumes and thus reduced risks for welders.

Genotoxicity and inflammatory potential of stainless steel welding fume particles: an in vitro study on standard vs Cr(VI)-reduced flux-cored wires and the role of released metals

Welders are daily exposed to various levels of welding fumes containing several metals. This exposure can lead to an increased risk for different health effects which serves as a driving force to develop new methods that generate less toxic fumes. The aim of this study was to explore the role of released metals for welding particle-induced toxicity and to test the hypothesis that a reduction of Cr(VI) in welding fumes results in less toxicity by comparing the welding fume particles of optimized Cr(VI)-reduced flux-cored wires (FCWs) to standard FCWs. The welding particles were thoroughly characterized, and toxicity (cell viability, DNA damage and inflammation) was assessed following exposure to welding particles as well as their released metal fraction using cultured human bronchial epithelial cells (HBEC-3kt, 5–100 µg/mL) and human monocyte-derived macrophages (THP-1, 10–50 µg/mL). The results showed that all Cr was released as Cr(VI) for welding particles generated using standard FCWs whereas only minor levels (< 3% of total Cr) were released from the newly developed FCWs. Furthermore, the new FCWs were considerably less cytotoxic and did not cause any DNA damage in the doses tested. For the standard FCWs, the Cr(VI) released in cell media seemed to explain a large part of the cytotoxicity and DNA damage. In contrast, all particles caused rather similar inflammatory effects suggesting different underlying mechanisms. Taken together, this study suggests a potential benefit of substituting standard FCWs with Cr(VI)-reduced wires to achieve less toxic welding fumes and thus reduced risks for welders.

Welding fume nanoparticles from solid and flux-cored wires: Solubility, toxicity, and role of fluorides

Welding fume particles are hazardous. Their toxicity likely depends on their composition and reactivity. This study aimed at exploring the role of sodium or other fluorides (NaF), which are intentionally added to flux-cored wire electrodes for stainless steel welding, on the solubility (in phosphate buffered saline) and toxicity of the generated welding fume particles. A multi-analytical particle characterization approach along with in-vitro cell assays was undertaken. The release of Cr(VI) and Mn from the particles was tested as a function of fluoride solution concentration. The welding fume particles containing NaF released significantly higher amounts of Cr(VI) compared with solid wire reference fumes, which was associated with increased cytotoxicity and genotoxicity in-vitro. No crystalline Na or potassium (K) containing chromates were observed. Cr(VI) was incorporated in an amorphous mixed oxide. Solution-added fluorides did not increase the solubility of Cr(VI), but contributed to a reduced Mn release from both solid and flux-cored wire fume particles and the reduction of Cr(VI) release from solid wire fume particles. Chemical speciation modeling suggested that metal fluoride complexes were not formed. The presence of NaF in the welding electrodes did not have any direct, but possibly an indirect, role in the Cr(VI) solubility of welding fumes.

Effects of mild steel welding fume particles on pulmonary epithelial inflammation and endothelial activation

Welders have an increased risk for cardiovascular disease (CVD) following exposure to welding fumes. The underlying mechanisms are largely unknown; however, oxidative stress, systemic inflammation, and endothelial dysfunction have been suggested as contributing factors to particle-induced CVD. We investigated effects of mild steel welding fume (MSWF) on three target cell types: macrophages, pulmonary epithelial, and vascular endothelial cells. Cells were exposed to MSWF at nontoxic doses for 6 h/day, for five consecutive days. The expression of 40 genes involved in inflammation, fibrosis, and endothelial activation was analyzed. Moreover, changes in the reactive oxygen species production and migration capacity of cells were assessed. The expression of matrix metallopeptidase 1 (MMP1) was induced in both epithelial and endothelial cells following repeated exposure to MSWF. Although MMP1 is important in inflammatory responses in vivo, this effect was not concurrent with changes in the inflammatory status, cell proliferation, and migration capacities, nor did it induce oxidative stress in the cells. Thus, repeated exposure with low doses of MSWF was sufficient neither for inducing inflammatory stress in epithelial cells and macrophages nor for endothelial activation, and higher concentrations of MSWF or the nonparticle fraction of MSWF may be critical in causing the increased risk of CVD observed among welders.

Bioactivity of Circulatory Factors After Pulmonary Exposure to Mild or Stainless Steel Welding Fumes.

Studies suggest that alterations in circulating factors are a driver of pulmonary-induced cardiovascular dysfunction. To evaluate, if circulating factors effect endothelial function after a pulmonary exposure to welding fumes, an exposure known to induce cardiovascular dysfunction, serum collected from Sprague Dawley rats 24 h after an intratracheal instillation exposure to 2 mg/rat of 2 compositionally distinct metal-rich welding fume particulates (manual metal arc welding using stainless steel electrodes [MMA-SS] or gas metal arc welding using mild steel electrodes [GMA-MS]) or saline was used to test molecular and functional effects of in vitro cultures of primary cardiac microvascular endothelial cells (PCMEs) or ex vivo organ cultures. The welding fumes elicited significant pulmonary injury and inflammation with only minor changes in measured serum antioxidant and cytokine levels. PCME cells were challenged for 4 h with serum collected from exposed rats, and 84 genes related to endothelial function were analyzed. Changes in relative mRNA patterns indicated that serum from rats exposed to MMA-SS, and not GMA-MS or PBS, could influence several functional aspects related to endothelial cells, including cell migration, angiogenesis, inflammation, and vascular function. The predictions were confirmed using a functional in vitro assay (scratch assay) as well as an ex vivo multicellular environment (aortic ring angiogenesis assay), validating the concept that endothelial cells can be used as an effective screening tool of exposed workers for determining bioactivity of altered circulatory factors. Overall, the results indicate that pulmonary MMA-SS fume exposure can cause altered endothelial function systemically via altered circulating factors.

Performance of composite polyester filter with magnetic NdFeB particles on filtering welding fume particles

Welding fume particles can pose serious health risks because of its nanoscaled size and pulmonary toxicity. The main components of welding fume particles are iron oxides, most of which are easily magnetized in a magnetic field and subject to magnetic attraction. According to this characteristic, we developed a magnetic composite filter composed of a polyester filter and neodymium iron boron (NdFeB) particles to improve the filtering effect on fume particles. The performance parameters of magnetic filter were studied experimentally. At 5 cm/s face velocity, the filtration efficiency and quality factor of magnetic filter #4 were 2.09 times and 1.55 times of those of filter #0 (no NdFeB particles coated), respectively. In the loading process, the particles accumulation did not weaken the magnetic attraction effect. The filtration efficiencies of magnetic and nonmagnetic filters for 600 nm particles increased by 10.53% at 14.65 g/m2 and 8.17% at 14.33 g/m2, respectively.

Mild steel and stainless steel welding fumes elicit pro-inflammatory and pro-oxidant effects in first trimester trophoblast cells.

ProblemAs more women join the skilled‐trade workforce, the effects of workplace exposures on pregnancy need to be explored. This study aims to identify the effects of mild steel and stainless steel welding fume exposures on cultured placental trophoblast cells.Method of studyWelding fumes (mild steel and stainless steel) were generously donated by Lincoln Electric. Electron microscopy was used to characterize welding fume particle size and the ability of particles to enter extravillous trophoblast cells (HTR‐8/SVneo). Cellular viability, free radical production, cytokine production, and ability of cells to maintain invasive properties were analyzed, respectively, by WST‐1, electron paramagnetic resonance, DCFH‐DA, V‐plex MULTI‐SPOT assay system, and a matrix gel invasion assay.ResultsFor all three welding fume types, average particle size was <210 nm. HTR‐8/SVneo cells internalized welding particles, and nuclear condensation was observed. Cellular viability was significantly decreased at the high dose of 100 µg/mL for all three welding fumes, and stainless steel generated the greatest production of the hydroxyl radical, and intracellular reactive oxygen species. Production of the cytokines IL‐1β and TNFα were not observed in response to welding fume exposure, but IL‐6 and IL‐8 were. Finally, the invasive capability of cells was decreased upon exposure to both mild steel and stainless steel welding fumes.ConclusionWelding fumes are cytotoxic to extravillous trophoblasts, as is evident by the production of free radicals, pro‐inflammatory cytokines, and the observed decrease in invasive capabilities.

Dependence of welding fume particle toxicity on electrode type and current intensity assessed by microalgae growth inhibition test

Welding fumes are a major source of metal oxide particles, ozone, carbon monoxide, carbon dioxide, nitrogen oxides, and many other toxic substances. Hazardous properties and the level of toxicity of welding fumes depend mostly on the welding electrode type and the welding regime parameters. The specific objective of this study was to evaluate the aquatic toxicity of metal welding fume particles in vivo on microalga Heterosigma akashiwo. The quantity and size of particles were measured by flow cytometry using a scattering laser light with a wavelength of 405 nm. The number of microalgae cells after 72 h and 7 days exposition with welding fume particle suspensions was evaluated by flow cytometry. Morphological changes of the microalga were observed by optical microscopy. The toxic effect was demonstrated as a significant reduction of cell density after exposure of microalgae to welding fume particles. The greatest impact on the growth of microalga was caused by particles with high rutile content. It was shown that the adverse effect of metal oxide particles depends more on the chemical composition of particles in welding fume while the number and dispersity of particles had no noticeable toxic influence on microalgae. The findings of this research confirm the fact that the toxicity of welding fume particles can be significantly reduced by using rutile-cellulose coated electrodes.

Respiratory deposition of ultrafine welding fume particles

The inhalation and the deposition of welding-generated ultrafine particles in welders’ respiratory tracts have been linked to severe pulmonary impairments. In the present study, a mobile aerosol lung deposition apparatus (MALDA) was developed and applied to study the respiratory deposition of ultrafine welding fume particles. The MALDA was constructed with a set of physiologically representative human tracheobronchial airway replicas made with high-resolution 3D printers. Ultrafine welding fume particles were generated in a welding fume chamber and delivered to the MALDA. A series of respiratory deposition experiments were carried out using the MALDA to investigate the deposition of ultrafine welding fume particles in different airway generations of the tracheobronchial airways. The results showed that the fractional deposition of ultrafine welding fume particle in the human tracheobronchial airways down to the 9th airway generation could be readily and systematically measured by the MALDA. The estimated cumulative respiratory deposition ranged from approximately 9–31% for ultrafine welding fume particles between 10 and 100 nm in diameter. The results acquired demonstrated that the MALDA developed has the potential to become a useful apparatus in the future to estimate the respiratory deposition of ultrafine particles in real workplaces.

High variability in toxicity of welding fume nanoparticles from stainless steel in lung cells and reporter cell lines: the role of particle reactivity and solubility

Millions of people in the world perform welding as their primary occupation resulting in exposure to metal-containing nanoparticles in the fumes generated. Even though health effects including airway diseases are well-known, there is currently a lack of studies investigating how different welding set-ups and conditions affect the toxicity of generated nanoparticles of the welding fume. The aim of this study was to investigate the toxicity of nine types of welding fume particles generated via active gas shielded metal arc welding (GMAW) of chromium-containing stainless steel under different conditions and, furthermore, to correlate the toxicity to the particle characteristics. Toxicological endpoints investigated were generation of reactive oxygen species (ROS), cytotoxicity, genotoxicity and activation of ToxTracker reporter cell lines. The results clearly underline that the choice of filler material has a large influence on the toxic potential. Fume particles generated by welding with the tested flux-cored wire (FCW) were found to be more cytotoxic compared to particles generated by welding with solid wire or metal-cored wire (MCW). FCW fume particles were also the most potent in causing ROS and DNA damage and they furthermore activated reporters related to DNA double- strand breaks and p53 signaling. Interestingly, the FCW fume particles were the most soluble in PBS, releasing more chromium in the hexavalent form and manganese compared to the other fumes. These results emphasize the importance of solubility of different metal constituents of the fume particles, rather than the total metal content, for their acute toxic potential.

Numerical simulation of welding fume lung dosimetry

Exposures to airborne particles and toxic gases generated by welding fabrication activities will potentially lead to various diseases. Accurate information on the transport and deposition of such aerosols in the respiratory system is critically needed for precise health risk assessments. To address the data demand mentioned above, a multiscale computational fluid-particle dynamics (CFPD) model was developed in this study. Specifically, a virtual fabrication shop was integrated with a virtual human in the numerical model to evaluate the effects of ventilation condition, particle size, and gas species on the lung uptakes of those welding fume particles and gases. Welding fume particle and gases transmission, transport, and deposition have been simulated and analyzed starting from the emission source to the subject-specific human respiratory system via oral inhalation. Spherical iron particles with diameters of 100, 190, and 830 nm were simulated. The transport and absorption of NOx and CO were predicted too. Steady-state inhalation with 11.87 L/min was applied with two different air filter ventilation conditions. The numerical results indicate that the ventilation condition can significantly influence welding gas transport and deposition. The pulmonary gas absorption rate is much higher at poor ventilation conditions. The air-tissue absorption coefficient is another crucial factor that can impact pulmonary gas absorption. The total particle deposition fractions (TDFs) from mouth/nose to generation 6 (G6) are less than 18.0%, and particles mostly deposit in the oral cavity. Regional and local particle deposition data demonstrate that particles tend to enter the two upper lobes more than the other three lobes. In summary, this study paves the way to build a personalized in silico tool based on CFPD models for noninvasive precise health risk assessments associated with different welding activities.

The pro-inflammatory stimulus of zinc- and copper-containing welding fumes in whole blood assay via protein tyrosine phosphatase 1B inhibition

An asymptomatic systemic inflammation after exposure to zinc- and copper-containing welding fumes has been described as mild form of metal fume fever in recent studies. Since chronic systemic inflammation leads to a higher cardiovascular risk, examining the inflammation with the underlying pathomechanism is necessary to estimate and hopefully prevent long-term effects of welding. We established a whole blood assay to investigate the effects of zinc- and copper-containing welding fume particles on the blood immune response. Increased levels of IL-6, IL-8, TNFα and IL-1β determined after 24 hours of exposure indicated an acute systemic inflammatory reaction. In vitro increases of IL-6 were comparable to in vivo increases of serum IL-6 levels in a study with welding fume exposure of human subjects. Inhibition of PTP1B was identified as one pathway responsible for the effects of zinc- and copper-containing welding fumes and therefore welding fume fever. In conclusion, the whole blood assay is a reliable and feasible method to investigate effects of zinc- and copper-containing welding fumes on the immune system and as a surrogate for systemic inflammation and welding fume fever. Future research can utilize whole blood assays to reduce and partially replace human exposure studies for further investigations of welding fume fever.

Influence of the gas metal arc welding regime parameters on the disperse and chemical composition of the welding fume particles

Influence of the gas metal arc welding regime parameters on the disperse and chemical composition of the welding fume particles