Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding

IF 3.8 Q2 MATERIALS SCIENCE, MULTIDISCIPLINARY

Journal of Advanced Joining Processes Pub Date : 2025-05-12 DOI:10.1016/j.jajp.2025.100311

Sungyo Jung , Gi Taek Oh , Seungjin Jung , Chungsik Yoon

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引用次数: 0

Abstract

Flux-cored arc welding (FCAW) generates hazardous byproducts such as welding fumes and hexavalent chromium (Cr(VI)), posing significant health and environmental risks. This study investigated the effectiveness of modifying specific flux components in flux-cored wires (FCWs) to reduce these emissions. One base FCW and ten flux-modified FCWs were tested under controlled conditions, capturing emissions for gravimetric and Cr(VI) analysis. Flux compositions were determined using X-ray fluorescence. Statistical analyses, including difference tests, correlation, and multiple linear regression, were conducted to evaluate the association between the content of flux components and emission rates. Sodium (Na) content in the flux was positively associated with increased emission of welding fumes and Cr(VI), while titanium (Ti) content showed a negative association. Increasing the contents of fluorine (F), potassium (K), and chromium (Cr) in the flux raised welding fume emission but reduced Cr(VI) emissions. Strategic adjustments in flux composition, specifically increasing Ti, silicon (Si) and zirconium (Zr) while decreasing Cr, K, Na, and F content, significantly reduced welding fume emissions by up to 32.4 % and Cr(VI) emissions by 95.4 %. These findings suggest that tailoring flux composition can effectively mitigate occupational and environmental hazards, enhance welder safety, and promote more sustainable FCAW practices without compromising welding performance.

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调整焊剂成分以控制焊剂芯弧焊中的焊烟和六价铬排放

药芯弧焊（FCAW）产生有害的副产品，如焊接烟雾和六价铬（Cr(VI)），构成重大的健康和环境风险。本研究探讨了改性药芯焊丝（FCWs）中特定助焊剂成分以减少这些排放的有效性。在受控条件下测试了一种碱性FCW和十种改性FCW，捕获排放物进行重量和Cr（VI）分析。用x射线荧光测定通量组成。采用差异检验、相关分析和多元线性回归等统计分析方法对通量组分含量与排放率之间的关系进行了评价。助焊剂中钠（Na）含量与焊烟和铬（VI）排放量的增加呈正相关，钛（Ti）含量呈负相关。增加焊剂中氟(F)、钾(K)和铬（Cr）的含量，提高了焊烟排放，但降低了Cr（VI）排放。对焊剂成分进行战略性调整，特别是增加Ti、硅（Si）和锆（Zr），同时降低Cr、K、Na和F含量，可显著降低焊接烟尘排放量达32.4%，降低Cr（VI）排放量达95.4%。这些发现表明，调整焊剂成分可以有效地减轻职业和环境危害，提高焊工的安全性，并在不影响焊接性能的情况下促进更可持续的FCAW实践。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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