1. Welding, Soldering, Brazing
Max Akhterov
Zettl Group Safety Talk
11/07/06

2. Welding
Welding is a materials joining process which produces coalescence of materials by heating them to suitable temperatures with or without the application of pressure or by the application of pressure alone, and with or without the use of filler material.
The American Welding Society
AWS distinguishes the welding processes according to:
Mode of energy transfer
Influence of capillary attraction in effecting distribution of filler metal in the joint
Groups of welding processes:
Arc welding
Brazing
Oxyfuel Gas Welding
Resistance Welding
Solid State Welding
Soldering
Other

3. Hazards 1. Fumes and Gases 2. Electric Shock 3. Radiation 4. Noise
5. Fire and Burns

4. Fumes and Gases
Fumes are solid particles which originate from welding consumables, the base
metal, and any coatings present on the base metal.
Possible effects of over-exposure (magnesium, copper, zinc, lead, chromium, etc.):
Irritation of eyes, skin, respiratory system
Symptoms: nausea, headaches, dizziness, metal fume fever
manganese overexposure can affect the central nervous system
resulting in impaired speech and movement
In confined spaces the gases might displace breathing air and cause asphyxiation
How to avoid:
Do not breathe the fumes
Use respiratory protection
Use enough ventilation or exhaust
Be sure the breathing air is safe

5. Electric Shock The voltage used in welding: 120 – 575 V
The current used in welding: 150 – 500 A
Possible effects of electric shock:
Spasms
Burns
Muscle paralysis
Death
How to avoid:
Properly install and ground the equipment
Wear dry, hole-free, insulating gloves and
protective clothing
Insulate yourself from the work piece
and ground

6. Radiation
Radiation is electromagnetic energy given off by the arc or flame that can injure eyes
and burn skin. Operator does not see ultraviolet and infrared radiation. Radiation is often
silent and undetected, yet injury occurs. Two type of radiation: Ionizing, Nonionizing.
Possible effects of radiation:
Skin burns
Eye damage
Skin cancer
Symptoms: “sand in the eyes”, feeling of pressure in the eyes, tearing, photophobia
How to avoid:
Use welding helmet with correct shade of filter plate
Protect skin with adequate gloves and clothing
Be aware of reflections from welding arcs

7. Noise
In welding noise may result from the process, the power source, or other equipment.
Excessive noise is a known health hazard.
Possible effects of noise:
Loss of hearing that may be either full or partial and either temporary or permanent
Hearing loss may be a temporary threshold shift from which the ears may recover if removed from the noise source
How to avoid:
Shield the source where practical
Reduce the intensity of the source
Use earmuffs

8. Fire and Burns
Welding processes produce molten metal, sparks, slag, and hot work surfaces. These can cause fire or burns.
How to avoid fire:
Remove combustible materials for a minimum radius of 10.7 meters around the work area
Cover or block all openings, such as doorways, windows, cracks, or other openings with
fire resistant material
Do not weld on or cut material having a combustible coating or internal structure
How to avoid burns:
Wear dry, hole-free insulating gloves
Wear oil-free protective garments such as leather gloves, heavy shirt, cuffless pants,
high shoes, and a cap
Use approved helmets and safety goggles

9. Personal Protective Equipment
Respiratory protection

10. Personal Protective Equipment
Eye safety
Safety eyewear should always be worn under the welding helmet to protect against flying debris when the helmet is raised to inspect work and when engaged in other welding activities, e.g. grinding, hammering.

11. 274 Le Conte Hall Oxy-fuel welding and cutting safety
(flame temperature 2000 C):
Before using an oxyhydrogen setup, ensure that
flammable materials such as grease, oil, paint,
sawdust, etc are cleared from the area
Use enough ventilation or exhaust
Shaded goggles with enclosed sides to protect
your eyes from glare sparks and splatter
Wear leather gloves to protect your hands from
burns. Clothes and shoes/boots appropriate for
welding.

12. Soldering Soldering safety (about 400°C):
Work only in well-ventilate areas
Use soldering support
Avoid touching the mains flex with the tip of the iron
Always return the soldering iron to its stand when not in use
Wash your hands after using solder

13. Resources EHS 0243 - Soldering Awareness Training
The American Welding Society:
Welding Guideline: