HEALTH HAZARDS OF WELDING

BY: NOAH EFFLER

NORTH CAROLINA GRADUATION PROJECT
SPRING 2016
ZIMMERMAN 3RD PERIOD
ENGLISH IV

Many people need to know what welding is because everyday life consists of objects that
have been welded together at one point, if they weren't welded the tools to build them was. The
car's a person drive the house they live in, the town everyone has grown up in is held together
because of welding, altho welding is a crucial job for society today, welding is also a
tremendous hazarde on the body.
What is welding, welding is defined as a process where two or more pieces of metal or
thermoplastics are fastened together by use of heat and pressure.(types of welding) Welding has
been around for quite a while but before welding a process known as forge welding was the
only means of joining two metal objects together. Forge welding consists of using a flame to heat
metal to extremely high temperature and then hammering each piece together until they become
one. This method was replaced around the time of the industrial revolution.(types of welding)
forge welding was replaced with the type of welding we know today that uses electricity heat and
pressure.
There are many types of welding not all forms of welding are the same some forms of
welding use gas while others use electricity(types of welding) The three main types commonly
heard and used are TIG (tungsten inert gas welding), MIG (metal inert gas welding), and Stick
(Shielded-metal arc welding).
TIG stands for Tungsten inert gas. Tungsten inert gas welding requires a major
amount of focus and skill due to the small area of space between the arc (types of welding) but
tungsten inert gas welding produces extremely strong high quality welds so high quality it is
commonly used to weld everything from bicycles to aircrafts, both commercial and military.
Tungsten inert gas requires additional filler placed inside the welding device as tungsten is
unique as it can be heated to a higher temperature before melting then all other metals.(types of

welding) Very little change has been made to gas tungsten arc welding since its release in
1941.(types of welding)
MIG is another commonly used welding
method when it was first developed it was
called (GMA) Gas metal arc it is also known
as (GMAW) or Gas metal arc
welding,technically the difference in the names are the type of gas used.(MIG welding) Gas
metal arc welding (GMAW) was created in the 1940s and was originally developed for use
with aluminum metals today this method is mostly used by those welders in the automotive
repair and manufacturing industries.(types of welding) Welding with MIG machines are really
easy, using MIG saves a lot of time and is the best method for large quantity of welding
work.(types of welding) The way a MIG machine works is MIG welders consist of a handle
with a trigger controlling a wire feed, feeding the wire from a spool to the weld joint. The wire is
similar to an endless bicycle brake cable, the wire runs through the line, which also has a gas
feeding through the same cable to the point of arc, the gas protects the weld from the air(MIG
welder) which makes MIG welding semi-automated this means that the welders still requires
skill, but that the MIG welding machine will constantly keep filling the joint being
welded.(MIG welding) Every MIG welder requires three things electricity to provide heat an
electrode to fill the joint, and shielding gas to protect the weld from the air.(MIG welding)
There are three types of gas or (shielding) used in MIG welding argon, carbon dioxide, and
helium. These three gases are typically used as a mixture depending on the metal that are being
welded.(MIG welding) The electrical for MIG is a little different then most MIG welding
unlike most other welding processes has one standard voltage type and polarity type. The voltage

used is D/C direct current, much like the

current in a car battery. Direct current flows in
one direction, from the negative to the
positive(MIG welding) in other words, the
handle in MIG welding is the positive side of
the circuit, or it may be said the electricity
flows from the metal into the welding
handle.(MIG welding)

The last commonly heard and used welding process is Stick welding or Shielded
metal arc welding (SMAW) it is called arc welding because an electrical current is created
between the welding device and the materials to
be welded which gives a arc like appearance.
This welding process needs no additional
shielding gas which makes this an ideal way to
weld in outdoor or windy environments like
construction sites. But because there is no gas
protecting the weld the electrode has flux which helps creates an arc also provides a protective
layer of slag which keeps contaminants out of the weld and will later be chipped away.(how to
stick weld) The first form of SMAW was created in 1938(types of welding) this process is
known to be the most popular and widely used processes in welding today.(types of welding)
Other less commonly used welding methods include Electroslag welding, Plasma arc
welding, and Submerged arc welding. Electroslag welding came into practice in the mid1950s(types of welding) and is a fast welding process used to join large materials such as thick
steel plates. The name electroslag was derived from the use of water filled copper areas within
the device, which were included and designed solely to prevent melted slag from pouring into
other areas as it liquefied.(types of welding) Plasma arc welding is very much like tungsten
inert welding the processes are often compared because they basically work in the same fashion,
the only difference is the type of torch.(types of welding) This method of welding came into
practice in 1954 although it is similar to TIG plasma welding also requires more concentration
and skill then TIG because of the smaller arc and the precision of the weld.(types of welding)
Finally there is submerged arc welding submerged arc welding can only be used on metals with

high iron content such as stainless steel and is a fast process but the electrical arc must
constantly be covered by flux in order to protect the metal from the atmosphere during the
welding process. This cover also prevents any welding splatter which makes it safer for welders
than some of the other forms of welding(types of welding) The reason it is named submerged
arc welding is because of its need to be submerged in a flux cover.
With every welding process there are a tremendous amount of hazards that occur. Every
type of welding process produces fumes, the visible part of the fume cloud is mainly particles of
metal, metal oxide and flux (if used)the exact level of risk from the fumes will depend on three
factors; how toxic the fumes are, how concentrated the fumes are, and how long the fumes are
being breathed in.(illness caused by welding fume and gases) For example fabricators, spend a
significant amount of time setting up a job before they pick up the welding torch to start welding.
conversely a production welder who is supplied with ready to cut parts and a jig to hold them and
will spend much more time actually welding. If you are assessing risk it is important to consider
how long a welder will actually be welding.(illness caused by welding fume and gases) Also if
you are in a confined place where the welding smoke can't leave the concentration of the smoke
will be much higher which means the welder is breathing in much more toxic fumes. Gases and
fine particles in welding fumes can cause dryness of the throat,tickling coughing or a tight chest.
But the effects tend to be short lived. Also many welders report flu like symptoms after
welding. The effects are often worse at the start of the working week. This if from a illness called
metal fume fever it is usually linked to welding or hot work on galvanised metals. High exposure
to mild steel weld fumes can also cause this illness. Metal fume fever does not usually have any
lasting ill effects.(Fume Facts-what is and what does it do to you) Other illnesses welding
smoke causes is irritation of the eyes, nose, and respiratory tract and cause coughing, wheezing,

shortness of breath, bronchitis, pulmonary edema(fluid in the lungs), and pneumonitis

(inflammation of the lungs). Gastrointestinal
effects, such as nausea, appetite loss, vomiting,
cramps and slow digestion, also have been
associated with welding smoke.(welding fume
health hazards) Not only that but studies show
that welders and those involved in brazing,
soldering and metal cutting have an increasing
risk of lung cancer and possible larynx and
urinary tract cancer. Large quantity of toxic substances in welding smoke, include cancer-causing
agents such as cadmium, nickel, beryllium chromium, and arsenic.(welding fume health
hazards) So the are some of the reasons why welding fumes is internationally classified as
possibly carcinogenic to humans.(health and safety executive) In addition to welding fumes
welders frequently work in a noisy environment and carry out other noisy operations such as
needle scaling and grinding. It is likely that a welders individual noise exposure will be affected
not only by their own work, but also by the work of their colleagues.(hearing loss and vibration
White Finger) Noise levels depend on several factors, the type of material being worked on and
what you are doing to that material for example, stainless steel tends to produce higher noise
levels than mild steel. So when addressing noise level under estimating noise could lead to
damaged hearing however over estimating noise exposure could lead to unnecessary expense or
over protection. Another negative effect on welders is frequent heavy lifting and handling this
can cause back injuries and upper limb disorders this accounts for a large proportion of reported
cases of ill health.

There are many different jobs welders can pursue. Welding is a common process in both
the manufacturing and construction industries, and there are well over 100 different welding
processes for specific applications. Many welders are certified in one or more welding technique
such as stick welding MIG welding and TIG welding welders are frequently employed in the
shipbuilding, automotive, and aerospace industries. Welders also join beams and girders in
commercial and residential construction. They may lay pipelines and work to build and maintain
power plants and refineries.(types of welding careers) The possibilities for a welder is endless
when it comes to finding a job.
Altho there is many hazards to welding there is many ways and technology created to
prevent health hazards. When it comes to fumes welders can optimise their shielding gas
compared to using pure argon, using a gas containing 98% argon and 2% hydrogen results in
significantly less ozone (cancer causing fume) production when TIG welding aluminum. When
doing this welders will see production benefits like reduced arc time and welding quality that can
be used to justify any additional costs for mixed gas.(Welding Fume-reducing the Risk) When
welding the concentration of harmful substances will be highest in the plume of fume that rises
from the weld point. As the plume rises it mixes with the surrounding air effectively diluting
itself. Fans can be used to forcibly dilute the fumes. The more air the fumes can mix with the
lower the concentration of harmful substances. By reducing the concentration of harmful
substances you reduce the level of risk, this is why it is important to try and work with your head
out of the rising plume.(Welding Fume-reducing the Risk) But if it isn't possible to use fans
other things can help to like turntables to manipulate the workpiece so the welder can weld in a
position where the fume rising away from their face.(Welding Fume-reducing the Risk) Welders
have other options to help prevent or reduce health hazards like ear plugs, gloves, masks, and

respirators are some of the options but with all of the safety hazards of welding there positions
have an element of danger associated with them welders receive above average compensation
due to the additional risk they are taking.(What are the Different Welding Jobs?)
Leonard Effler a welder for multiple welding businesses such as Trinity industries, Buck
Stove, Welding Unlimited, PRP (performance Rail Products), and Appalachian Stove says
throughout his 12 year career he's been certified in MIG welding Stick welding and TIG welding.
He's has multiple problems that was due to welding without enough safety equipment he says
some are respiratory like wheezing, coughing it's also gave him headaches diarrhea and multiple
times hes actually had to stop welding because
it affected him so bad. He also noticed his
eyesight gotten worse and believes that welding
was a major part of that. He thinks that welding
is fine as long as you have the adequate
ventilation and safety precautions he believes
that they have the technology to prevent any
hazards associated with welding but most
welding businesses don't have the budget for the that kind of safety equipment so welders are
stuck with what the business can afford. The way this could be prevented is if they drop the
prices of better welding safety equipment.
Welding is a crucial job for society today, but is also a tremendous hazard on the
body. The common life span for a welder is 50 years, This is why people need to learn more
about what welding is, the types of welding, hazards of welding, the different jobs welders are
associated with and the technology that is provided to welders to make welding a little safer, so

people can keep the things they enjoy that welders provide. Then hopefully people will start
providing more safety resources to welders.