Author: Vanessa 2 Apr. 2025 Category: Applications
In modern manufacturing workshops, the fumes generated by welding operations are like invisible ghosts, threatening the health of millions of welders every day. These seemingly ethereal fumes actually contain a large amount of toxic substances, and their degree of harm is no less than that of industrial waste gas. They are like invisible killers, quietly eroding the health of welders.
Ⅰ. Chemical composition and physical properties of welding fumes
Welding fumes are a mixture of ultrafine particles formed by the condensation of metals after gasification under the action of high-temperature arcs. The complexity of its composition is comparable to that of a chemical reagent library. Take common stainless steel welding as an example:
1. Metal oxides (accounting for 60-90% of the total):
- Hexavalent chromium (Cr⁶⁺): a highly toxic component in stainless steel welding smoke that can penetrate cell membranes and directly damage DNA structure;
- Manganese oxide (MnO₂): long-term contact leads to “manganese poisoning” and nervous system damage;
- Iron oxide (Fe₂O₃): particle size 0.1-1μm, easy to deposit in the lungs.
2. Gaseous pollutants:
- Ozone (O₃): a strong oxidant produced by the arc, with a concentration of up to 0.5-5ppm;
- Carbon monoxide (CO): the concentration exceeds 100ppm during flux-cored wire operation;
- Hydrogen fluoride (HF): produced during aluminum welding, corrosive to the respiratory tract;
3. Particle characteristics:
- Particle size distribution: 80% of particles are <1μm (can reach the alveoli directly);
- Production: about 5-15g/kg welding rod for manual arc welding;
- Chargeability: electrostatic force enhances particle penetration;
According to the test results of the National Institute for Occupational Safety and Health (NIOSH), the amount of metal dust inhaled by an ordinary welder in 8 hours of work is equivalent to smoking 30 cigarettes. What is more worrying is that more than 80% of these harmful substances have a particle size of less than 1 micron, which is equivalent to 1/50 of the diameter of a human hair. They can easily bypass the natural defense barrier of the human respiratory tract, reach deep into the alveoli and accumulate in the body.
Ⅱ. Health hazards of welding smoke: comprehensive invasion from lungs to genes
Welding smoke is classified as a Class 1 carcinogen by the International Agency for Research on Cancer (IARC), and its hazards present multi-system and progressive characteristics:
1. Respiratory system damage
Acute symptoms: metal fume fever (fever, chills, cough)
Chronic lesions:
- Pneumoconiosis (pulmonary fibrosis)
- Asthma incidence increased by 3 times
- Lung cancer risk increased by 30-40% (chromium, nickel exposure)
2. Nervous system toxicity
Manganese poisoning causes Parkinson‘s-like symptoms:
Hand tremors, balance disorders; mood swings, memory loss; blood-brain barrier penetration leading to decreased cognitive function
3. Other systemic impacts
Hexavalent chromium induces nasal septum perforation
Zinc fume causes “brass foundry fever“
Cadmium fumes cause electrolyte disorders
Statistics from the German Social Accident Insurance Agency (DGUV) show that among welders who do not take effective protective measures, the incidence of chronic bronchitis is as high as 7 times that of ordinary workers, the risk of lung cancer increases by nearly 40%, and the average professional life span is shortened by 12-15 years. What is more serious is that the residual fume on the welding suit will also endanger the health of the welder’s family through secondary transmission, especially it may cause irreversible effects on the development of children.
Ⅲ. Trenntech’s intelligent filtration solution: comprehensive protection from source to breathing zone
1. Source capture technology
Flexible suction arm system:
- 360° adjustable suction nozzle, capture efficiency>90%
- Wind speed 0.5-1.5m/s stepless adjustment
- High temperature resistance design (instantaneous resistance to 350℃)
Overall solution for welding room:
- Negative pressure control system (pressure difference -5 to -10Pa)
- Top exhaust + bottom air supply design
- Air exchange volume 2000-5000m³/h optional
- Three-stage filtration system
| Filter level | Technical features | Removal target | Efficiency standard |
| Pre-filtration | Metal mesh + cyclone separation | >10μm sparks and large particles | EN 779 G4 |
| Main filtration | Nanofiber coated filter cartridge | 0.3-10μm metal oxide | ISO 16890 ePM1 |
| Post-filtration | Chemical adsorption layer (activated carbon + alumina) | Ozone, hydrogen fluoride and other gaseous substances | EN 13779 R1 |
3. Intelligent monitoring system
Real-time monitoring:
- Particle concentration (laser scattering principle)
- Filter cartridge pressure difference (wireless transmission)
- Gas composition (electrochemical sensor)
Early warning function: filter element replacement reminder (AI prediction algorithm); automatic leakage alarm and other functions.
Actual measured data from a certain automobile production workshop showed that the Trenntech system reduced the PM2.5 concentration at the welding station from 800μg/m³ to below 35μg/m³, and the exposure to chromium was reduced by 98%, which fully complies with the requirements of the EU REACH regulations.
Welding fume protection is not a cost, but a respect for the value of workers’ lives. Choosing Trenntech means choosing to go hand in hand with responsibility and choosing scientific protection, so that every welder can work with peace of mind and every family can be happily reunited. If you need to know more about welding fume protection solutions, please feel free to contact Trenntech’s professional technical team at any time, and we will serve you wholeheartedly.