There is no doubt that laser welding is an effective and efficient technique in the manufacturing industry. However, there are worries about the possible health risks linked to the release of harmful fumes by the welding process. The presence of heavy metals, chemicals, or dust particles in these fumes may have a negative impact on employees’ health. So, it is important to know the risks of laser welding fume emissions.
In this article, we are going to shed light on all the adversities of these fumes. We will also discuss the steps to take to prevent them from negatively impacting employees and the work environment as little as possible. Continue reading to learn more.
Laser Welding Fume, Attention to Micro Particles
The issue of welding fumes is present in all welding operations, including laser welding. This is true, even though laser welding is often characterized as cleaner than other welding methods.
Laser welders give off fumes that are easily incapacitating at high temperatures, but you can not see them. Researchers have now developed infrared imaging techniques to study the laser welding beam, which releases invisible fumes. These fumes are made up of extremely tiny particles that are excessively volatile. The obvious fact is workers are more at risk when inhaling particulate matter of a smaller size.
In order to join materials, laser welding technology makes use of a laser beam, which is a source of extremely concentrated heat. The laser beam creates a joint by heating and melting the material’s edges. During this process, welding fumes are developed. As is already the case with other welding techniques, these fumes must be absolutely sucked in at the source. This must be done before they reach the respiratory tract of the operators. The fumes must also be controlled before they are dispersed into the environment.
After that, they can be disposed of outdoors. They can also be filtered using abatement systems made for this purpose.
Factors Affecting Fume Formation
There are some factors that control the amount and chemical makeup of laser welding fumes. Let’s look into them:
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Materials Being Welded
Material differences are caused by three factors: metal concentration, surface coatings, and impurity levels. These differences can cause laser welding to emit fumes that vary in quantity and composition. As an example, chromium and nickel fumes are more prevalent when welding stainless steel than when welding carbon steel. Therefore, it is critical to assess possible health risks by analyzing material composition prior to welding.
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Welding Parameters
Welding parameters like laser power, welding speed, and beam focusing can also impact the nature of the fumes produced. Typically, the amount of fume generated is directly proportional to the power of the laser and the welding speed. Careful adjustment of these parameters can help reduce fume emissions and, at the same time, maintain the desired welding quality. However, it takes research and testing to find the best welding parameters.
Problems with Laser Welding Dust and Fumes
Even a small amount of laser fume can cause significant problems. In fact, any laser welding emissions, be they fumes or dust, are harmful to the welding equipment and the people around. Let’s have a more clear discussion on this.
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Health Risks of Laser Welding Emissions
The laser-created fumed particles are incredibly small, frequently measuring less than a micron. When inhaled, these microscopic particles have the potential to clog airways, spread throughout the body, or become stuck in lung tissue. Depending on the materials used, these particles can cause cancer, lung damage, neurological damage, and kidney disease.
Microplastics that are breathed in when plastic is welded can cause asthma and other lung diseases. Once fumed plastics get into the bloodstream, they can cause problems with the nervous system, heart, and immune system. On top of that, plastic fumes are suspected to cause cancer.
Then again, laser welding of metals, like resistance welding, produces toxic particulates. Metallic weld fume can cause cancer and has been linked to lung, urinary tract, and larynx cancers. Besides, toweling galvanized or coated materials or using fillers produces more fumes and more dangerous emissions. Such emissions can include iron, lead, aluminum, cadmium, cobalt, copper, chromium, zinc, manganese, beryllium, molybdenum, and other toxic metals. These can depend on the base materials used and any coatings that are present.
There are many harmful conditions linked to many metals and metal oxides-
- Metal fume fever
- Manganism (a neurological disease like Parkinson’s)
- Damage to the kidneys and nervous system
- Stomach ulcers
- Lung disease
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Laser Welding Emissions Impact Equipment and Weld Seam Quality
A normal area for robotic laser welding is an enclosure. If there is a lack of control over weld fumes, they can accumulate inside the cage and affect the laser’s workings. Besides, if there is a lot of dust in the air, the laser beam will bend and spread out. That means the beam will have less power and accuracy and the weld will not be as good. Interference levels that are too high could mean that the weld doesn’t meet quality standards for precision and power.
Laser welding fumes could also hurt the laser welding machine. Dust can gather on the optical lens, in the diaphragm, or in the shutter mechanisms. All of these can slow down the laser or make it shut down without warning.
Controlling Contaminating Laser Welding Fume: 3 Solutions
Controlling laser welding fumes can help keep tools running smoothly and improve the quality of the weld seams. It may also reduce the potential threat to humans. Here are the three best ways to put the fume under control:
1. Perform Source Capture to Improve Efficiency
The best way to capture welding fumes is to put a fume extraction nozzle next to the source of the fumes. If you can not put a nozzle there due to any mechanical reason, the fume extraction should be as close as it can be. For optimal fume extraction, the nozzle should move with the laser beam during the operation.
Just one fume and dust collector is enough for situations where more than one process produces fumes. For instance, a single welding fume extractor can suffice for manufacturers who simultaneously conduct laser cleaning and welding.
2. Ventilation Systems
A key measure to lessen exposure to laser welding fumes is to install efficient ventilation systems at welding workstations. There are usually two types: general ventilation and local ventilation. General ventilation moves air around the workspace. Conversely, local ventilation gets rid of fumes right where they come from. The choice of the best ventilation system to use will depend on welding process details, workspace dimensions, and the number of workstations.
3. Air Filtration
Another option for reducing laser welding fume emissions is to install an air filter. To ensure that the air in the workplace is free of harmful substances, filtration systems can be used. These systems can include mechanical filters, electrostatic filters, chemical absorbers, and so on. When dealing with extremely dangerous substances, air filtration becomes absolutely vital in order to ensure the utmost safety for the people involved.
Conclusion
Laser welding may be cleaner than traditional welding methods, but it still produces fumes. Because the particles are so small, the fumes from laser welding are invisible and spread easily. These fumes, depending on the materials and welding parameters, can contain toxic metals and cause severe health issues.
Not only that, they can also significantly reduce the productivity of the entire welding process. All these negative impacts necessitate effective fume control methods. Some of them include source capture, ventilation systems, and air filtration. If fumes are controlled using any of these methods, the weld will be better, and the equipment will last longer. Besides, it guarantees a safer environment for the workers by cutting down on harmful emissions and pollution.
It’s true that cutting down on emissions significantly increases welding efficiency. However, that’s not the first condition of an outstanding weld. An excellent welding machine from a reliable supplier is what truly makes or breaks the welding deal. And you are getting exactly that from Fiber Laser Welder. Please contact us if you need precision welding solutions.
