Control of Cr6+ emissions from gas metal arc welding using a silica precursor as a shielding gas additive.

Hexavalent chromium (Cr(6+)) emitted from welding poses serious health risks to workers exposed to welding fumes. In this study, tetramethylsilane (TMS) was added to shielding gas to control hazardous air pollutants produced during stainless steel welding. The silica precursor acted as an oxidation inhibitor when it decomposed in the high-temperature welding arc, limiting Cr(6+) formation. Additionally, a film of amorphous SiO(2) was deposited on fume particles to insulate them from oxidation. Experiments were conducted following the American Welding Society (AWS) method for fume generation and sampling in an AWS fume hood. The results showed that total shielding gas flow rate impacted the effectiveness of the TMS process. Increasing shielding gas flow rate led to increased reductions in Cr(6+) concentration when TMS was used. When 4.2% of a 30-lpm shielding gas flow was used as TMS carrier gas, Cr(6+) concentration in gas metal arc welding (GMAW) fumes was reduced to below the 2006 Occupational Safety and Health Administration standard (5 µg m(-3)) and the efficiency was >90%. The process also increased fume particle size from a mode size of 20 nm under baseline conditions to 180-300 nm when TMS was added in all shielding gas flow rates tested. SiO(2) particles formed in the process scavenged nanosized fume particles through intercoagulation. Transmission electron microscopy imagery provided visual evidence of an amorphous film of SiO(2) on some fume particles along with the presence of amorphous SiO(2) agglomerates. These results demonstrate the ability of vapor phase silica precursors to increase welding fume particle size and minimize chromium oxidation, thereby preventing the formation of hexavalent chromium.

Determination of silica coating efficiency on metal particles using multiple digestion methods.

Nano-sized metal particles, including both elemental and oxidized metals, have received significant interest due to their biotoxicity and presence in a wide range of industrial systems. A novel silica technology has been recently explored to minimize the biotoxicity of metal particles by encapsulating them with an amorphous silica shell. In this study, a method to determine silica coating efficiency on metal particles was developed. Metal particles with silica coating were generated using gas metal arc welding (GMAW) process with a silica precursor tetramethylsilane (TMS) added to the shielding gas. Microwave digestion and Inductively Coupled Plasma-Atomic Emission Spectroscopy (ICP-AES) were employed to solubilize the metal content in the particles and analyze the concentration, respectively. Three acid mixtures were tested to acquire the appropriate digestion method targeting at metals and silica coating. Metal recovery efficiencies of different digestion methods were compared through analysis of spiked samples. HNO(3)/HF mixture was found to be a more aggressive digestion method for metal particles with silica coating. Aqua regia was able to effectively dissolve metal particles not trapped in the silica shell. Silica coating efficiencies were thus calculated based on the measured concentrations following digestion by HNO(3)/HF mixture and aqua regia. The results showed 14-39% of welding fume particles were encapsulated in silica coating under various conditions. This newly developed method could also be used to examine the silica coverage on particles of silica shell/metal core structure in other nanotechnology areas.

Decreasing biotoxicity of fume particles produced in welding process.

Welding fumes contain heavy metals, such as chromium, manganese, and nickel, which cause respiratory diseases and cancer. In this study, a SiO(2) precursor was evaluated as an additive to the shielding gas in an arc welding process to reduce the biotoxicity caused by welding fume particles. Transmission electron micrographic images show that SiO(2) coats on the surface of welding fume particles and promotes particle agglomeration. Energy dispersive X-ray spectroscopy further shows that the relative amount of silicon in these SiO(2)-coated agglomerates is higher than in baseline agglomerates. In addition, Escherichia coli (E. coli) exposed to different concentrations of pure SiO(2) particles generated from the arc welding process exhibits similar responses, suggesting that SiO(2) does not contribute to welding fume particle toxicity. The trend of E. coli growth in different concentrations of baseline welding fume particle shows the most significant inhibition occurs in higher exposure concentrations. The 50% lethal logarithmic concentrations for E. coli in arc welding particles of baseline, 2%, and 4.2% SiO(2) precursor additives were 823, 1605, and 1800 mg/L, respectively. Taken together, these results suggest that using SiO(2) precursors as an additive to arc welding shielding gas can effectively reduce the biotoxicity of welding fume.