Total and Soluble Metal Contents in Flux-Cored Arc Welding Fumes

The chemical composition and solubility of metals in welding fumes is thought to be related to the welder health but is not well characterized. We quantified and compared the total (insoluble + soluble) and soluble metal contents in fumes from flux-cored arc welding using non-stainless steel (FCAW/NSS) and stainless steel (FCAW/SS) wire. Welding was performed in an American Welding Society standard fume collection chamber. The total content of 13 analyzed metals was significantly higher in FCAW/NSS fumes than in FCAW/SS fumes (51.6 +/- 5.7 vs. 40.2 +/- 5.2%, p < 0.001). Soluble metal content was significantly higher in FCAW/SS fumes than in FCAW/NSS fumes (15.5 +/- 5.8 vs. 6.49 +/- 2.4%, p < 0.001) due to the presence of potassium and sodium. Different proportions of each element were observed between welding types. Iron, magnesium, and aluminum were significantly higher in FCAW/NSS fumes, whereas chromium, nickel, and potassium were more common in FCAW/SS fumes. The metal composition of FCAW fumes was more similar to that of shielded metal arc welding fumes than that of gas metal arc welding fumes. It seems unnecessary to measure soluble iron, nickel, aluminum, and barium to compare with their soluble ACGIH-TLVs at the FCAW welding process. But chromium should be specified in terms of its valance and solubility.