Fume particle size distribution and fume generation rate during arc welding of cast iron

This study measured the fume particle size distribution and fume generation rate during arc welding of cast iron and estimated the generation rate of respirable dust. In addition, the generation rate of particles with a diameter of 0.3 µm or less was estimated. In this experiment, three types of filler materials (mild steel wire, stainless steel wire, and mild steel covered electrodes) with main constituents of Fe or Fe-Cr-Ni, as proposed previously by the authors, were used. The welding methods were gas metal arc welding and shielded metal arc welding. The fumes measured in this research contained 73–91% respirable dust, and the fume generation rates were in the range of 1.96–12.2 mg/s. The results of this study were as follows: (i) the welding current affects the generation rate of respirable dust, and it is highly likely that the higher the fume generation rate, the more respirable dust is generated; (ii) the generation rates of respirable dust at low and high current were highest when mild steel covered electrodes and stainless steel wire was used, respectively; and (iii) the generation rate of particles with a diameter of 0.3 µm or less was highest when stainless steel wire is used.