Abstract
This paper presents the influence of synthetic rutile addition to the electrode flux on the shielded metal arc welding emissions. A systematic study was conducted by modifying the electrode flux composition with synthetic and conventional rutile combinations. The fume particulates emitted during welding were sampled using an AWS F1.2 standard fume test chamber, and its concentration was determined through gravimetric analysis. Online monitoring of arc stability, droplet transfer characteristics, and spatter formations was performed using digital storage oscilloscope, high-speed camera, and infrared camera devices, respectively. The UVC and ozone concentrations in the arc atmosphere were also measured using standard procedures. The results revealed that the addition of synthetic rutile up to 50% could reduce the fume emissions by as much as 31.4% compared to the conventional electrode. The present study also focused on the reduction of hexavalent chromium (Cr(VI)), a hazardous and carcinogenic chemical species in welding fumes. In order to achieve a combined reduction in the concentration of hexavalent chromium and fume, Zn, a reactive metal, was added to the electrode flux of the experimental electrodes. The primary mechanism of reduction in fumes and Cr(VI) concentration was recognized from the study as the decrease in the surface tension of the pendent liquid droplet ensued by the presence of fine-grained TiO2 in the synthetic rutile. Apart from lowering fume emissions, the experimental electrodes achieved a deposition efficiency of up to 61.9%, which was appreciably higher than that of the conventional electrode.
Similar content being viewed by others
Availability of data and material
Not applicable.
Code availability
Not applicable.
References
MacLeod JS, Harris MA, Tjepkema M, Peters PA et al (2017) Cancer risks among welders and occasional welders in a national population-based cohort study: Canadian census health and environmental cohort. Saf Health Work 8(3):258–266
Rissone NMR, Farias JP, Bott IS, Surian ES (2002) ANSI/AWS A5. 1–91 E6013 rutile electrodes: the effect of calcite. 113–124
Zhang Y, Coetsee T, Yang H, Zhao T, Wang C (2020) Structural roles of TiO2 in CaF2-SiO2-CaO-TiO2 submerged arc welding fluxes. Metall Mater Trans B 51(5):1947–1952
Akhgar BN, Pazouk M, Ranjbar M et al (2012) Application of Taguchi method for optimization of synthetic rutile nano powder preparation from ilmenite concentrate. Chem Eng Res Des 90(2):220–228
Shojaei V, Schaffie M, Mohebbi A et al (2014) Upgrading of ilmenite using KOH sub-molten salt process assisted by mechanical activation. Mater Manuf Process 29(10):1284–1288
Chen G, Ling Y, Li Q et al (2020) Highly efficient oxidation of Panzhihua titanium slag for manufacturing welding grade rutile titanium dioxide. J Mater Res Technol 9(4):7079–7086
Sivapirakasam SP, Mohan S, Santhosh Kumar MC et al (2015) Welding fume reduction by nanoalumina coating on electrodes - towards green welding process. J Clean Prod 108:131–144
Mohan S, Sivapirakasam SP, Santhosh Kumar MC et al (2015) Welding fumes reduction by coating of nano-TiO2 on electrodes. J Mater Process Technol 219(May):237–247
Sivapirakasam SP, Mohan S, Santhosh Kumar MC et al (2017) Control of exposure to hexavalent chromium concentration in shielded metal arc welding fumes by nano-coating of electrodes. Int J Occup Environ Health 23(2):128–142
Vishnu BR, Sivapirakasam SP, Sathpathy KK et al (2018) Cr 6+ reduction in welding fumes by nano composite coatings on stainless steel manual metal arc welding electrodes. Process Saf Environ Prot 114:334–346
Lunau FW (1967) Ozone in arc welding. Ann Occup Hyg 10(3):175–188
Vishnyakov VI, Kiro SA, Ennan AA (2020) Reducing of UV radiation intensity, ozone concentration and fume formation in gas metal arc welding. Aerosol Sci Eng 4(3):192–199
Chadyšiene R, Girgždys A (2009) Assessment of ultraviolet (UV) radiation from technical sources. J Environ Eng Landsc Manag 17(3):164–170
Kudo Y, Sakasai A, Hamada K et al (2004) Mechanical tests on the welding part of SS316LN after heat treatment for Nb3Sn superconducting conductor. J Nucl Mater 329–333(1–3 Part A):634–638
Kim JB, Sohn I (2014) Effect of alumina and extended basicity on the viscosity and structure in the TiO2-MnO-Al2O3–8.64 ZrO2–2.77 Na2O welding flux system. ISIJ Int 54(3):657–663
Kim JB, Sohn I (2014) Effect of SiO2/Al2O3 and TiO2/SiO2 ratios on the viscosity and structure of the TiO2–MnO–SiO2–Al2O3 welding flux system. ISIJ Int 54(9):2050–2058
Kim JB, Sohn I (2013) Influence of TiO2/SiO2 and MnO on the viscosity and structure in the TiO2–MnO–SiO2 welding flux system. J Non-Cryst Solids 379:235–243
EN ISO Standard: ISO 15011-1:2009. Health and safety in welding and allied processes – Laboratory method for sampling fume and gases generated by arc welding – Part 1: Determination of emission rate and sampling for analysis of particulate fume. https://www.iso.org/obp/ui/es/#iso:std:iso:15011:-1:ed-2:v1:en. Accessed 29 Jul 2022
Srinivasan K, Balasubramanian V (2011) Effect of surface tension metal transfer on fume formation rate during flux-cored arc welding of HSLA steel. Int J Adv Manuf Technol 56(1–4):125–134
Okuno T, Ojima J, Saito H (2001) Ultraviolet radiation emitted by CO2 arc welding. Ann Occup Hyg 45(7):597–601
Dennis JH, Mortazavi SB, French MJ, Hewitt PJ et al (1997) The effects of welding parameters on ultraviolet light emissions, ozone and Cr(VI) formation in MIG welding. Ann Occup Hyg 41(1):95–104
Liu HH, Wu YC, Chen HL (2007) Production of ozone and reactive oxygen species after welding. Arch Environ Contam Toxicol 53(4):513–518
Fernandes R, van Os BJH, Huisman HDJ (2013) The use of hand-held XRF for investigating the composition and corrosion of Roman copper-alloyed artefacts. Herit Sci 1(1):1–7
Zhang J, Coetsee T, Wang C (2020) Element transfer behaviors of fused CaF2-SiO2 fluxes subject to high heat input submerged arc welding. Metall Mater Trans B 51(1):16–21
Zhang J, Coetsee T, Dong H, Wang C (2020) Element transfer behaviors of fused CaF2-TiO2 fluxes in EH36 shipbuilding steel during high heat input submerged arc welding. Metall Mater Trans B 51(5):1953–1957
Vishnu BR, Sivapirakasam SP, Satpathy KK, Albert SK, Chakraborty G (2018) Influence of nano-sized flux materials in the reduction of the Cr (VI) in the stainless steel welding fumes. J Manuf Process 34(March):713–720
Bachmann B, Siewert E, Schein J (2012) In situ droplet surface tension and viscosity measurements in gas metal arc welding. J Phys D Appl Phys 45(17)
Wang J, Kalivoda M, Guan J et al (2012) Double shroud delivery of silica precursor for reducing hexavalent chromium in welding fume. J Occup Environ Hyg 9(12):733–742
Dennis JH, French MJ, Hewitt PJ, Mortazavi SB, Redding CAJ (2002) Control of occupational exposure to hexavalent chromium and ozone in tubular wire arc-welding processes by replacement of potassium by lithium or by addition of zinc. Ann Occup Hyg 46(1):33–42
Almostaneer H, Cadigan C, Liu S, Olson DL, Richards R, Liang HJ (2011) Hydrocarbon-metal reactions during metal arc welding under oil (MAW-UO). Sci Technol Weld Join 16(7):619–629
Zhang J, Leng J, Wang C (2019) Tuning weld metal mechanical responses via welding flux optimization of TiO2 content: application into EH36 shipbuilding steel. Metall Mater Trans B 50(5):2083–2087
Acknowledgements
The authors would like to express their gratitude to the Director of the National Institute of Technology (NIT), Tiruchirappalli, for her unwavering encouragement and support throughout this endeavor. The authors would like to express their heartfelt gratitude to Cochin Minerals and Rutile Limited, Kerala, for supplying the raw materials necessary for the successful completion of this work.
Author information
Authors and Affiliations
Contributions
Rahul Madhusoodhanan: conceptualization, methodology, investigation, and writing of the original draft. Sivapirakasam Suthangathan Paramashivan: formal analysis, supervision, resources, and writing which included review and editing. Sreejith Mohan: methodology, validation, formal analysis, and investigation. Vishnu B. Rajeshwari: formal analysis and investigation. Guruvayurappan Murali: review and editing.
Corresponding author
Ethics declarations
Ethics approval and consent to participate
Not applicable.
Consent for publication
All authors agreed to publish this manuscript in the International Journal of Advance Manufacturing Technology and confirmed that this work has not been published anywhere before.
Competing interests
The authors declare no competing interests.
Additional information
Publisher's note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
Springer Nature or its licensor holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.
About this article
Cite this article
Madhusoodhanan, R., Paramashivan, S.S., Mohan, S. et al. Manufacture of low fume welding electrode using synthetic rutile flux material. Int J Adv Manuf Technol 121, 8197–8208 (2022). https://doi.org/10.1007/s00170-022-09834-5
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-022-09834-5