Fume generation in gas metal arc welding

193 Pages·2017·5.98 MB·English

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Doctoral Dissertations Student Scholarship
Winter 1996
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Robert V. Albert
University of New Hampshire, Durham
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Albert, Robert V., "Fume generation in gas metal arc welding" (1996). Doctoral Dissertations. 1925.
https://scholars.unh.edu/dissertation/1925
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FUME GENERATION IN GAS METAL
ARC WELDING
BY
ROBERT V. ALBERT
B.S. University Of Connecticut, 1979
M.S. Syracuse University, 1982
A DISSERTATION
Submitted to the University Of New Hampshire
In Partial Fulfillment of
The Requirements for the Degree of
Doctor of Philosophy
in
Engineering
December 1996
Reproduced with permission of the copyright owner. Further reproduction prohibited without permission.
UMI Number: 9717849
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This dissertation has been examined and approved
Dissertation director, Gail D. Ulrich, Prof of
Chemical Engineering
Stephan S.T. Fan, Prof of Chemical Engineering
T-
^ — -___________________
Russell T. Carr, Associate Prof of Chemical
Engineering
P T.
.
Palligarna T. Vasudevan Associate Prof of
Chemical Engineering
David W. Watt Associate Prof of Mechanical
Engineering
\ %
Date
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ACKNOWLEDGMENTS
I would like to thank my advisor Professor Ulrich
for his guidance and belief in my ability to do this. I
would like to thank Professor Thomas Eager of M.I.T. for
bringing assistance and expertise to the project. I would
like to thank Professor Joseph Brain of the Harvard
School of Public Health for his help in toxicology
evaluation.
I would like to thank John Deere and company and the
UNH office of Sponsored Research for finacial support. I
would also like to thank L-tec Incorporated and Hobart
Brothers Company, and Torit Division of the Donaldson
Company, for donations of equipment.
I would like to thank Professor Fan and the
University of New Hampshire faculty for the many years of
patience and learning.
I would like to thank Johnathan Newell and Nancy
Littlefield for their help throughout the years. Finally
I would like to thank Harvard researchers Krishna Murthy
and Jim Antonini for their collaboration in collecting
and evaluating fume samples.
iii
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DEDICATION
I dedicate this to my wife Jill and daughters Jean
and Gwen. I would also like to recognize my parents for
their support.
iv
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TABLE OF CONTENTS
Acknowledgements....................................... iii
Dedication...............................................iv
Table Of Contents........................................ v
List Of Figures........................................ vii
List Of Tables.......................................... ix
Abstract..................................................x
CHAPTER
I. INTRODUCTION.........................................1
II BACKGROUND...........................................5
Historical Perspective..............................5
Fume In General.....................................8
Physiological Effects..............................10
Arc welding In General.............................13
Fume Generation....................................20
Results Gleaned From Prior literature.............31
Effects Of Voltage, Current and Shield Gas On GMAW
Fume Rates......................................... 36
Gas Metal Arc Welding Transfer.................... 40
Epidemiology....................................... 47
The Lung's Defense Systems........................ 47
Lung Evaluation....................................48
Literature Review..................................49
NIOSH.............................................. 49
American Welding Society...........................51
Sferlazza & Beckett................................52
III Theory..............................................59
Mechanisms......................................... 59
Fume Formation Model...............................61
Fume Generation....................................75
Steady State and Drop Temperature................. 85
Drop Formation....................................109
IV Experimental...................................... 118
Equipment and Methods.............................118
Harvard Exper iments...............................121
Results........................................... 123
v
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Fume Generation Data.............................123
Particle Properties..............................126
UNH Analysis..................................... 126
Harvard Analysis.................................130
V Discussion..........................................138
Fume Generation Rates.............................138
Question #1 Answer...............................141
Question #2 Answer...............................153
Question #3 Answer...............................156
Question #4 Answer.............................. 162
VI Conclusion..........................................167
Bibliography....................................... 171
vi
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