A semi-empirical model of the fume formation from gas metal arc welding

The control of exposure to welding fume is necessary to meet health and safety obligations. The work reported here examines the fundamentals of welding-fume formation. A physical chemistry model of the metal vapour mechanism for fume formation has been developed for non short-circuiting transfer gas metal arc welding (GMAW). The model includes the important contribution made by direct condensation of metal vapour onto the weldpool and workpiece, in removing a substantial fraction of the fume. The model shows that droplet size and wire feed speed control the fine fume formation rate. The understanding developed so far, indicates that the smaller the detached droplet size, the lower the total fume formation rate. The physics behind this is explained. The model gives an insight into how process modification might be used to control fume at source. Control at source is believed to be the most cost-effective and energy-efficient technique for dealing with welding fume. It is anticipated that the understanding gained from this project will be applied to determine the practical limits for the control of welding fume at its source.