Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding
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...
Saved in:
| Main Authors: | , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2025-06-01
|
| Series: | Journal of Advanced Joining Processes |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S2666330925000329 |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1850153947485962240 |
|---|---|
| author | Sungyo Jung Gi Taek Oh Seungjin Jung Chungsik Yoon |
| author_facet | Sungyo Jung Gi Taek Oh Seungjin Jung Chungsik Yoon |
| author_sort | Sungyo Jung |
| collection | DOAJ |
| description | 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. |
| format | Article |
| id | doaj-art-c44d7d28c6544c1a875a0f4596ff8b07 |
| institution | OA Journals |
| issn | 2666-3309 |
| language | English |
| publishDate | 2025-06-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Advanced Joining Processes |
| spelling | doaj-art-c44d7d28c6544c1a875a0f4596ff8b072025-08-20T02:25:35ZengElsevierJournal of Advanced Joining Processes2666-33092025-06-011110031110.1016/j.jajp.2025.100311Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc weldingSungyo Jung0Gi Taek Oh1Seungjin Jung2Chungsik Yoon3Department of Environmental Health Sciences, Graduate School of Public Health, Seoul National University, 1802, Nambusunhwan-ro, Gwanak-gu, Seoul, 08786, Republic of KoreaDepartment of Environmental Health Sciences, Graduate School of Public Health, Seoul National University, 1802, Nambusunhwan-ro, Gwanak-gu, Seoul, 08786, Republic of KoreaChosun Welding Co., Ltd., 34-13, Hwasan 2-gil, Onsan-eup, Ulju-gun, Ulsan, 45009, Republic of KoreaDepartment of Environmental Health Sciences, Graduate School of Public Health, Seoul National University, 1802, Nambusunhwan-ro, Gwanak-gu, Seoul, 08786, Republic of Korea; Institute of Health and Environment, Seoul National University, 1802, Nambusunhwan-ro, Gwanak-gu, Seoul, 08786, Republic of Korea; Corresponding author.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.http://www.sciencedirect.com/science/article/pii/S2666330925000329Flux cored arc weldingWelding fumesHexavalent chromiumEmission controlCleaner productionSustainable welding technologies |
| spellingShingle | Sungyo Jung Gi Taek Oh Seungjin Jung Chungsik Yoon Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding Journal of Advanced Joining Processes Flux cored arc welding Welding fumes Hexavalent chromium Emission control Cleaner production Sustainable welding technologies |
| title | Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| title_full | Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| title_fullStr | Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| title_full_unstemmed | Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| title_short | Tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| title_sort | tailoring flux composition to control welding fume and hexavalent chromium emissions in flux cored arc welding |
| topic | Flux cored arc welding Welding fumes Hexavalent chromium Emission control Cleaner production Sustainable welding technologies |
| url | http://www.sciencedirect.com/science/article/pii/S2666330925000329 |
| work_keys_str_mv | AT sungyojung tailoringfluxcompositiontocontrolweldingfumeandhexavalentchromiumemissionsinfluxcoredarcwelding AT gitaekoh tailoringfluxcompositiontocontrolweldingfumeandhexavalentchromiumemissionsinfluxcoredarcwelding AT seungjinjung tailoringfluxcompositiontocontrolweldingfumeandhexavalentchromiumemissionsinfluxcoredarcwelding AT chungsikyoon tailoringfluxcompositiontocontrolweldingfumeandhexavalentchromiumemissionsinfluxcoredarcwelding |