One objective of the program is to contribute to improved health and safety of welders through research into the control and reduction of welding fume. A second objective is the development of integrated voltage reduction devices to reduce the risk of electric shock and eliminate fatalities due to electrocution whilst welding in confined and damp spaces. A third objective is to conduct ergonomic research aimed at improving the conditions under which welding is conducted.

The first step towards the achievement of these objectives will be the completion of the following project:

Understanding welding fume formation
This is a continuation of successful research that has revealed how two different types of fume are formed in gas metal arc welding.

This year has seen the characterisation of fume morphology over a range of welding conditions. The most exciting development has been the understanding of how potentially carcinogenic hexavalent chrome is formed in welding fume. Arc modelling studies have revealed that condensation of metal vapour onto the workpiece and weldpool reduces the amount of fine fume formed by a significant fraction. A full understanding of the fume forming process will need to take metal vapour condensation into account. To our knowledge, this is the first time that the significance of metal vapour transfer in fume formation has been understood.

Future work will be aimed at the development of a semi-empirical model of fume formation accounting for metal vapour transfer and a thermochemical model to predict concentration of chemical species in fume. It is also intended to apply previously developed understanding to practical welding procedures to provide indicators to limit generation of fume at source. Control at source is believed to be the most cost effective and energy efficient technique for dealing with welding fume.

There will be close collaboration between the research provider partners and the appropriate Technical Panel of WTIA in developing further projects related to achieving the objectives of this Sub-program.