Welding Fume Extraction

Welding is a vital process in metal fabrication, but it also creates hazardous fumes that can post a severe threat to your health. These fumes contain a mixture of gases, particles, and metal oxides that can cause respiratory problems, metal fume fever, and even cancer. Implementing an effective welding fume extraction system is essential to safeguard the health of welders and those in the vicinity. 

Different types of welding that require welding fume extraction

Gas metal arc welding (GMAW/MIG)

Continuously fed, consumable wire electrode melts to form the weld and requires external shielding gas to protect the molten metal. It is a versatile process for welding thin to thick sections of steel, aluminum, and stainless steel. MIG welding is common in automotive and general fabrication applications.

Flux-cored arc welding (FCAW)

Similar to MIG welding, but the consumable electrode contains a core filled with flux. This flux provides additional shielding and allows for deeper weld penetration. It is often used in outdoor applications due to its tolerance to wind, in thicker sections where extra material deposition is needed, or in situations where external shielding gas might be impractical.

Gas tungsten arc welding (GTAW/TIG)

TIG welding uses a non-consumable tungsten electrode to create the intense heat for melting the base metal. A separate filler rod can be added to create the weld and it requires external shielding gas. TIG welding is known for producing high quality, clean welds. It is ideal for applications demanding precise control and minimal splatter.

Submerged arc welding (SAW)

Heat is generated by an arc formed beneath a blanket of continuously fed granular flux. The flux protects the molten metal and removes impurities. The high-deposition rate makes it suitable for long seams and thick plate applications, like shipbuilding and heavy equipment manufacturing. 

Electroslag welding (ESW)

Heat is generated by the electrical resistance of molten slag formed between a consumable electrode and the workpiece. Deep weld penetration is achieved. There are limited applications where this type of welding is the best option. Applications with thick material where deep penetration is required, like boiler and pressure vessel fabrication. ESW is a complex process requiring specialized equipment and training.

Oxyacetylene welding

This uses a high-temperature flame produced by the combustion of acetylene and oxygen to melt the metal. Oxyacetylene welding is often used in sheet metal work, repair and maintenance, and artistic metalworking.

Resistance welding

Heat is generated by the electrical resistance offered by the contact area between the workpieces. Resistance welding is most widely used in automotive manufacturing and assembly lines due to its speed and automation capabilities.

Welding fumes contain a mix of metal particles and gasses. Unlike many other processes, the fumes are often directly in the welder’s breathing area. Welding fume extraction removes hazardous materials from the area. As a result, welders are protected from exposure.

A source capture system consists of a welding fume extractor that uses hoods, downdraft tables, or fume arms. These are called capture points. Through these, fumes are extracted from each welding station. This is especially important if exposure must be tightly limited.

An ambient system circulates all the air in an area through the filters. Often, this air returns to the area after filtration. The number of times that the air is replaced in an hour depends on two factors: First, the size of the space. Second, the amounts of fumes or dust in the air.

CMAXX dust and fume collector on a welding fume extraction installation

Possible Equipment

Welding fumes may be combustible. Dust testing can establish what types of fire and explosion features are needed to meet OSHA and NFPA standards. Further, metal dust produced by welding may be very combustible. Please see our white paper on combustible dust for more details.

For welding and other metal fume applications, DeltaMAXX cartridge filters provide the necessary efficiency for small particle capture. These filters can capture particles as small as 0.3 microns. In addition, the system may include HEPA after-filters if the fumes contain especially hazardous materials like hexavalent chromium. These secondary filters are an extra barrier against the escape of toxic materials.

Please see the case studies below. These are examples of how Imperial Systems has helped other companies solve their welding fume extraction problems.