Fume formation from spatter oxidation during arc welding

Abstract

Spatter and fume formation rates during arc welding both increase and decrease in a similar manner as welding parameters change. Previously, this fume–spatter relationship has been attributed to evaporation of the spatter caused by oxidation. In this work, a simulated spatter oxidation test did not detect significant fume formation, but high speed videography showed fume trails behind large spatter droplets. Heat balance calculations show that only spatter droplets larger than a few millimeters evaporate and produce fume in significant amounts. Since most spatter particles are smaller than 2 mm, it is not likely that evaporation from spatter contributes significantly to fume. It is proposed that the correlation between spatter and welding fume is instead related to how the temperature of the welding surface affects formation rates of both spatter and fume.

Keywords

WELDING FUME SPATTER FORMATION RATE HEAT BALANCE DROPLET VAPORISATION

Get full access to this article

View all access options for this article.

References

Gray

C. N.

, Hewitt

P. J.

and Hicks

: in Proc. Int. Conf. ‘Weld pool chemistry and metallurgy’, Cambridge, UK, 167–176; 1980, Cambridge, TWI.

Gray

C. N.

, Hewitt

P. J.

and Hicks

: in Proc. Int. Conf. ‘Weld pool chemistry and metallurgy’, Cambridge, UK, 197–203; 1980, Cambridge, TWI.

Deam

, Bosworth

, Chen

, French

, Haidar

, Lowke

, Norrish

, Tyagi

and Workman

: in Proc. Int. Weld. Joining Res. Conf. ‘Technological developments and advances for Australian industry’, Melbourne, Australia, (ed. B. Gross and C. Smallbone), paper 17; 1997, Silverwater, Welding Technology Institute of Australia.

Quimby

J. B.

and Ulrich

G. D.

: Weld. J., 1999, 78, 142–149.

Zimmer

A. T.

, Baron

P. A.

and Biswas

: J. Aerosol Sci., 2002, 33, 519–531.

Gray

C. N.

, Hewitt

P. J.

and Dare

P. R. M.

: Weld. Met. Fabr., 1982, 50, 393–397.

Hewitt

P. J.

and Hirst

A. A.

: Ann. Occup. Hyg., 1991, 35, 223–232.

Vardelle

, Vardelle

, Li

K.-I.

, Fauchais

and Themelis

N. J.

: Pure Appl. Chem., 1996, 68, 1093–1099.

Vardelle

, Vardelle

, Zhang

, Themelis

N. J.

and Gross

: J. Therm. Spray Technol., 2002, 11, 244–252.

10.

Heile

R. F.

and Hill

D. C.

: Weld. J., 1975, 54, 201–210.

11.

Eichhorn

and Oldenburg

T. H.

: in Proc. Conf. ‘Health hazards and biological effects of welding fumes and gases’, (ed. R. M. Stern et al.), 51–54; 1985, Copenhagen, Danish Welding Institute.

12.

Willingham

D. C.

and Hilton

D. E.

: Weld. Met. Fabr., 1986, 54, 226–229.

13.

Hilton

D. E.

and Plumridge

P. N.

: Weld. Met. Fabr., 1991, 59, 555–560.

14.

Castner

H. R.

: Weld. J., 1995, 74, 59–68.

15.

Castner

H. R.

: Weld. J., 1996, 75, 393s–401s.

16.

QuimbyandG

. Ulrich: Weld. J., 1999, 78, 142s–149s.

17.

Liao

M. T.

and Chen

W. J.

: Mater. Chem. Phys., 1998, 55, 145–151.

18.

Jelmorini

, Tichelaar

G. W.

and G. J. P. M. Van den heuvel: ‘Droplet temperature measurements in arc welding’; 1997, Report 212-411-77, Paris, IIW.

19.

Lancaster

J. F.

: Proc. IEEE Part B, 1987, 134, 233.

20.

Poirier

D. R.

and Geiger

G. H.

: ‘Transport phenomena in materials processing’; 1994, Warrendale, PA, TMS.

21.

Turkdogan

E. T.

, Grieveson

and Darken

L. S.

: J. Phys. Chem., 1963, 67, 1647–1654.

22.

Brown

R. L.

and Stein

S. E.

: in ‘NIST Chemistry WebBook, NIST Standard Reference Database Number 69’, (ed. P. J. Linstrom and W. G. Mallard); 2003, Gaithersburg, MD, National Institute of Standards and Technology (http://webbook.nist.gov).

23.

Haidar

: J. Appl. Phys., 1999, 85, 3448–3459.

24.

Block-Bolten

and Eagar

T. W.

: in Proc. Conf. ‘Trends in welding research in the United States’, New Orleans, LA, USA, (ed. S. A. David); 1981, Metals Park, OH, American Society for Metals.

25.

Steinberg

, Wilson

and Benz

: Combust. Flame, 1992, 91, 200–208.

26.

Sun

, Dobashi

and Hirano

: Combust. Sci. Technol., 2000, 150, 99–117.

27.

Kheifets

: Auto. Weld. USSR, 1986, 39, 49–51.

28.

Dreizin

E. L.

: Combust. Explo. Shock, 2003, 39, 681–693.

29.

Villeminot

: Soudage Techniques Connexes, 1967, 21, 367.

30.

Mendez

, Jenkins

N. T.

and Eagar

T. W.

: in Proc. Conf ‘Gas metal arc welding for the 21st century’, Orlando, FL, USA, 325–332; 2000, Miami, FL, American Welding Society.

31.

Eickhoffand

S. T.

T. W. Eagar: Weld. J., 1990, 69, 382s–388s.

32.

Dwyer

O. E.

: ‘Boiling liquid–metal heat transfer’; 1976, Hinsdale, IL, American Nuclear Society.

33.

Turkdogan

E. T.

, Grieveson

and Darken

L. S.

: J. Metals, 1962, 7, 521–526.

34.

and Apps

R. L.

: Weld. Met. Fabr., 1982, 50, 307–316.

35.

and Apps

R. L.

: Weld. Met. Fabr., 1983, 51, 168–170.