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Arc Welding: Unit 11: Physical and Chemical Hazards and Safety Measures in Various Operation

Arc welding is a process that uses electricity to create enough heat to melt metal and join it. It uses a welding power supply to create an electric arc between a metal electrode and base material. Gas welding uses fuel gases and oxygen to weld or cut metals, producing flames up to 3,773 K. Forging is a process that shapes metal through hammering or pressing to deliver compressive forces with a die or hammer, producing parts with high strength and fatigue resistance. Safety precautions for forging include proper equipment use and personal protective equipment. Physical hazards of forging include risks from drawing compounds and welding emissions. Casting involves pouring liquid material like metal into a mold and allowing it to solidify to form a shaped part,

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36 views6 pages

Arc Welding: Unit 11: Physical and Chemical Hazards and Safety Measures in Various Operation

Arc welding is a process that uses electricity to create enough heat to melt metal and join it. It uses a welding power supply to create an electric arc between a metal electrode and base material. Gas welding uses fuel gases and oxygen to weld or cut metals, producing flames up to 3,773 K. Forging is a process that shapes metal through hammering or pressing to deliver compressive forces with a die or hammer, producing parts with high strength and fatigue resistance. Safety precautions for forging include proper equipment use and personal protective equipment. Physical hazards of forging include risks from drawing compounds and welding emissions. Casting involves pouring liquid material like metal into a mold and allowing it to solidify to form a shaped part,

Uploaded by

Yogi Kawar Ganga Nath
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© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Unit 11: Physical and chemical hazards and safety measures in

various operation

Arc Welding: Arc welding is a welding process that is used to join metal to metal
by using electricity to create enough heat to melt metal, and the melted metals when
cool result in a binding of the metals. It is a type of welding that uses a welding
power supply to create an electric arc between a metal stick ("electrode") and the
base material to melt the metals at the point of contact. Arc welders can use
either direct (DC) or alternating (AC) current, and consumable or non-
consumable electrodes. Arc welding processes may be manual, semi-automatic, or
fully automated. Today it remains an important process for the fabrication of steel
structures and vehicle.

Gas Welding: Oxy-fuel welding (commonly called oxyacetylene welding, oxy


welding, or gas welding in the U.S.) and oxy-fuel cutting are processes that use
fuel gases and oxygen to weld or cut metals. Pure oxygen, instead of air, is used to
increase the flame temperature to allow localized melting of the workpiece material
(e.g. steel) in a room environment. A common propane/air flame burns at about
2,250 K (1,980 °C; 3,590 °F), a propane/oxygen flame burns at about 2,526 K
(2,253 °C; 4,087 °F), an oxyhydrogen flame burns at 3,073 K (2,800 °C; 5,072 °F)
and an acetylene/oxygen flame burns at about 3,773 K (3,500 °C; 6,332 °F).

In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results
when two pieces are heated to a temperature that produces a shared pool of molten
metal. The molten pool is generally supplied with additional metal called filler. Filler
material depends upon the metals to be welded.
Forging: Forging is a manufacturing process involving the shaping of a metal
through hammering, pressing, or rolling. These compressive forces are delivered
with a hammer or die. Forging is often categorized according to the temperature at
which it is performed—cold, warm, or hot forging.

A wide range of metals can be forged. Typical metals used in forging include carbon
steel, alloy steel, and stainless steel. Very soft metals such as aluminum, brass, and
copper can also be forged. The forging process can produce parts with superb
mechanical properties with minimum waste. The basic concept is that the original
metal is plastically deformed to the desired geometric shape—giving it higher fatigue
resistance and strength. The process is economically sound with the ability to mass
produce parts, and achieves specific mechanical properties in the finished product.

Safety Precautions in Forging Shop


Some safety precautions in forging shop to followed while performing forging
operation to avoid injuries and accidents are listed below:

1. Always avoid the use of damaged hammers.


2. Never try to strike a hardened surface with a hardened tool.
3. No person should stand in line with the flying objects.
4. Always use the proper tongs tool to grip and lift objects according to the
type of work.
5. The anvil should always be clean and free from moisture and grease
while in use.
6. Always wear proper clothes such as apron, foot-wears and goggles.
7. The handle of the hammer should always be tightly fitted in the head of
the hammer.
8. Always put out the fire in the forge before leaving the forging shop.
9. Always keep the working space clean and tidy.
10. Proper safety guards should be provided on all revolving parts.
11. Head of the chisel should be free from burrs and should never be allowed
to spread.
12. During machine forging, always observe the safety rules prescribed for
each machine.
13. One must have the thorough knowledge and working of the forging
machine before going to operate it.

Physical and chemical hazards by Forging:


Chemical hazards specific to stamping typically arise from two main sources:
drawing compounds (i.e., die lubricants) in actual press operations and welding
emissions from assembly of the stamped parts. Drawing compounds (DCs) are
required for most stamping. The material is sprayed or rolled onto sheet metal
and further mists are generated by the stamping event itself. Like other
metalworking fluids, drawing compounds may be straight oils or oil emulsions
(soluble oils). Components include petroleum oil fractions, special lubricity
agents (e.g., animal and vegetable fatty acid derivatives, chlorinated oils and
waxes), alkanolamines, petroleum sulphonates, borates, cellulose-derived
thickeners, corrosion inhibitors and biocides. Air concentrations of mist in
stamping operations may reach those of typical machining operations, although
these levels tend to be lower on average (0.05 to 2.0 mg/m 3). However, visible
fog and accumulated oil film on building surfaces are often present, and skin
contact may be higher due to extensive handling of parts. Exposures most
likely to present hazards are chlorinated oils (possible cancer, liver disease,
skin disorders), rosin or tall oil fatty acid derivatives (sensitizers), petroleum
fractions (digestive cancers) and, possibly, formaldehyde (from biocides) and
nitrosamines (from alkanolamines and sodium nitrite, either as DC ingredients
or in surface coatings on incoming steel). Elevated digestive cancer has been
observed in two automotive stamping plants. Microbiological blooms in
systems that apply DCs by rolling it onto sheet metal from an open reservoir
can pose risks to workers for respiratory and dermatological problems
analogous to those in machining operations.
Welding of stamped parts is often performed in stamping plants, usually
without intermediate washing. This produces emissions that include metal
fumes and pyrolysis and combustion products from drawing compound and
other surface residues. Typical (primarily resistance) welding operations in
stamping plants generate total particulate air concentrations in the range 0.05
to 4.0 mg/m3. Metal content (as fumes and oxides) usually makes up less than
half of that particulate matter, indicating that up to 2.0 mg/m 3 is poorly
characterized chemical debris. The result is haze visible in many stamping
plant welding areas. The presence of chlorinated derivatives and other organic
ingredients raises serious concerns over the composition of welding smoke in
these settings and strongly argues for ventilation controls. Application of other
materials prior to welding (such as primer, paint and epoxy-like adhesives),
some of which are then welded over, adds further concern. Welding production
repair activities, usually done manually, often pose higher exposures to these
same air contaminants. Excess rates of lung cancer have been observed
among welders in an automotive stamping plant.

Casting:
Casting is a manufacturing process in which a liquid material is usually poured into
a mold, which contains a hollow cavity of the desired shape, and then allowed to
solidify. The solidified part is also known as a casting, which is ejected or broken out
of the mold to complete the process. Casting materials are usually metals or
various time setting materials that cure after mixing two or more components
together; examples are epoxy, concrete, plaster and clay. Casting is most often used
for making complex shapes that would be otherwise difficult or uneconomical to
make by other methods.
Safety Tips
Followings are few safety tips that one should know if he/she is dealing with casting
process or alloys:

1. Wear eye protection, gloves, spats (covering top of feet), and thick clothing
protecting all exposed skin on arms and legs. NO polyester or synthetic
clothing.
2. Sand Floor in pouring area shall be clear of all objects not involved in pouring.
3. Clamp or weight up molds that require it.
4. Metal added to heat must be free of moisture and impurities.
5. Metal added to heat during melt must be preheated.
6. Skimmers and other melting tools must be preheated before use.
7. Move Slowly while removing crucible from furnace and moving to mold.
8. Do not look into exhaust during operation.
9. Inspect crucibles before use.
10. Inspect propane lines.
11. Use outdoors only.
12. No alcohol or drug use.
13. Wear respiratory protection while melting copper-base alloys (brass, bronze).
Machining:
Machining is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The
processes that have this common theme, controlled material removal, are today
collectively known as subtractive manufacturing,[1] in distinction from processes of
controlled material addition, which are known as additive manufacturing. Exactly
what the "controlled" part of the definition implies can vary, but it almost always
implies the use of machine tools (in addition to just power tools and hand tools).
Machining is a part of the manufacture of many metal products, but it can also be
used on materials such as wood, plastic, ceramic, and composites.[2] A person who
specializes in machining is called a machinist. A room, building, or company where
machining is done is called a machine shop. Much of modern-day machining is
carried out by computer numerical control (CNC), in which computers are used to
control the movement and operation of the mills, lathes, and other cutting machines.

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