Protecting Welders: Fume Extraction in Aluminum Welding Processes

Welding aluminum can be more challenging than welding other metal materials because it is a highly conductive metal. Aluminum is a lightweight and highly conductive metal that is used in a range of industries, including automotive, aerospace, and construction. When it comes to welding, however, aluminum presents its own set of unique challenges that require specific techniques and consideration.

Due to its high thermal conductivity, aluminum requires more heat to weld when compared to other metals, which can make it more difficult to control the welding process and avoid distortion or warping of the material.

High thermal conductivity is not the only challenge when it comes to welding aluminum materials, there is also the obstacle of the formation of oxide layers on the surface of aluminum that can interfere with the process and weaken the weld, if not removed before the welding process. The correct filler material is also critical when welding aluminum – the most common filler metals are 4043 and 5356 because they are compatible with the composition of aluminum alloys.

Learn More Aluminum Welding Fumes

A machine operator welding on aluminum while smoke and fumes arise.

Welding on aluminum can create various dangers because the machining process produces combustibles that can ignite and cause an explosion. Aluminum has a low melting point and can catch fire easily if the welding process generates excessive heat. Welding aluminum generates fumes that can be hazardous to human health, particularly when inhaled over a long period. Additionally, welding aluminum can also result in electric shock, eye damage, and noise pollution.

The most common aluminum welding processes are TIG (tungsten inert gas) welding and MIG (metal inert gas) welding. TIG welding is excellent for thin aluminum sheets and MIG is better for thicker sections. During TIG or MIG welding, it is crucial to use the correct techniques and settings to control the heat input and prevent warping or distortion.

Aluminum welding produces hazardous fumes that can be harmful to the health and safety of employees. Welding on aluminum generates fumes that generate during the welding process when high temperatures vaporize the aluminum, flux, or filler metal.

Welding aluminum fumes contain various compounds like aluminum oxide and aluminum nitride — to name a couple. Overexposure to the fumes that develop when welding on aluminum can result in respiratory issues in the nose and throat and neurological symptoms such as headaches, fatigue, and tremors. Long-term exposure increases the risk of lung diseases including asthma and bronchitis and can lead to cancer.

A welder working on a metalworking project and using a FumeXtractors fume arm to extract smoke and fumes from above the source.

OSHA has found that respiratory issues caused by exposure to aluminum fumes constitute a material health impairment. Because workers exposed to arc welding fumes have previously not been protected by a permissible exposure limit, OSHA is establishing a PEL of 5 mg/m3 TWA for these fumes. These exposure limits protect machine operators and staff in the welding area from potential risks associated with breathing in aluminum fumes.

It is crucial to follow proper extraction and filtration methods and to avoid overheating the aluminum, as this can produce a higher volume of fumes and increase exposure risks. To eliminate exposure to aluminum welding fumes, it is important to utilize fume extraction systems and ventilation.

Outfitting your facility with fume extractors will eradicate airborne contaminants at the source before they enter breathing zones. Fume extractors are especially useful when welding in confined spaces or when working with large pieces of aluminum that require multiple welds. FumeXtractors systems can be stationary or portable and used across a variety of machining processes.

As a secondary solution to fume extraction systems, machine operators should use personal protection equipment like a respirator, to further minimize exposure to fumes.

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Overall, Fume extraction is essential to health and safety when welding on aluminum. Utilizing fume extraction systems can greatly minimize exposure risks and make working with aluminum safe for welders. Contact our specialists to learn more about welding aluminum and fume extraction.

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Protecting Welders: Fume Extraction in Aluminum Welding Processes

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