02.12.10: Welding Safety

Sometimes it's the things you can't see that can kill you! 

You know, one of the most satisfying things in life is to create a custom work of art by cutting and welding metal together. Whether it's a car or truck or bike or whatever... to have a machine that allows you to join metal at a molecular level is truly an amazing thing that has to be experienced to be fully understood.

Unfortunately, a tool that has this kind of power also has the power to inflict some serious damage, and most everybody knows how important proper safety gear is when you are welding. However, there are some hidden dangers that go way beyond the heat, and fire, and bright light that are usually associated with welding. I am talking about hidden dangers that can form in the air and do a lot more damage then give you a welder tan, or drop hot cherries down your shirt. I am talking about poison gas, and not the kind you get from Taco Bell.

A lot of people use brake cleaners and solvents to clean up old, crusty parts prior to welding them together. No problem, if you get everything nice and clean and dry. If you don't, there can be some serious problems lurking like a rattlesnake in the form of an overlooked drop of cleaner. How you ask? Well some brake cleaners, (Brake-Kleen for example) have a main ingredient called tetrachloroethylene. If you'll look you can see it listed right on the label. Now at this point you may be thinking..."So what?... well if you will read a little further down the label of the can, you will see that when this chemical is exposed to excessive heat and Argon gas, which is used in MIG and TIG welding, it produces a gas called Phosgene…and this is where things get really nasty.

Phosgene gas can be fatal with a dose as small as four parts per million which means if there is a drop of this cleaner hidden in a crack, and you hit it with your torch, the resulting tiny puff of smoke can kill you! But even if you don’t die, you may wish you were dead because there is no antidote for Phosgene poisoning, and some of the long term effects are chronic bronchitis and emphysema. There is also the risk of permanent kidney, liver, and pancreas damage, and any number of other really bad things...all from a gas that nobody has ever heard of, and most of us can't even pronounce!

So what can you do? Simple... Be aware of what you are doing. Read the warning labels on the cans of the things you are using, and understand how they may react to other tools and equipment you may be using. And above all, DON'T GET IN A HURRY, because that is where most of us make some really big mistakes. Remember, there is no project in this world that is worth the life or health of yourself or those around you, and all it takes is just a little pre-planning and preparation to make sure you will be welding safely for years to come.

So, what are you waiting for? Get out there and fire up those welders and build something cool!

Stacey David.

Comments

[Buddy Lindblom]

Thanks Stacey, very informative. I have been welding for over 25 years and did not know that. I will certainly pay attention to that

Buddy

[Ray Cross]

I want to thank you my father has performed welding repairs to farm and construction equipment for years as well as having a large collection of antique cars that he performs all of the repairs and restorations to. I will absolutely be making sure that he knows about this gas. Thanks again because you very well may have helped my family be able to have my father around longer simply by this little segment on your program made me come to your website to check out what I had heard and seen.

[Chuck]

Looking to purchase a small MIG unit for car work and I often use brake clearner for cleaning up metal parts.

You do an excellent job of covering the technical as well as safety matters for gear heads.

Thanks for the excellent tip and guidance much appreciated!

[Luke Albers]

I have been welding for 20 years. About 3 months ago I was repairing a structural member of a machine that also acted as a hydraulic reservoir. I thought brake cleaner (the exact one shown on the show) would be a great way to get the oil out of the cracks... bad idea. I guess I know now why I was coughing uncontrollaby. I'm lucky it wasn't worse by the sound of things. Another valuable lesson learned.

[Gary Farmer]

Always-ALWAYS wear a fume rspirator.Charcoal filter is the best.
Been welding since 77 and still have clean lungs!

[disappointed viewer]

i needed to put this some where. the last show, about speed racer, was the biggest pile of crap i have ever seen in my life! Soo many projects to finish, and that crap is what is what they air. the WHOLE show is commercials anyway, what the hell! make it worth watching please.

[Cisco]

HEAVY METAL

First like to say benn a fan since you were on trucks second i had the epsiode rec on dvr on hevy metal and i been working on a 83 chevy 3/4 ton 4x4 and really want a duramax under the hood and just cant seem to find one were did you get one for project heavy metal thanx

[Welding Certification]

I have to say WOW! I have more safety training then I thought I needed but no one ever mentioned brake cleaner. We are always warned about having a fire watch, wearing a respirator and the dangers of suffocation from shielding gas.

Can welding get any more dangerous? I guess it does!

Thanks for that tip,

Go Welding.Org

[south jersey mike]

thanks stacey good info will pass this on to others

[Robert L. Hernandez]

I bought a welder and have registered for a welding class in a community college. Something like this is a treasure. This is the first time here in this web site, but I plan on making this a regular visit. I am 57 years old and plan on re-restoring my 65 mustang. Yep! A lady rearended me, but I didn't give up the car. Yes, it will be a father and son and grandson and great grandson, build. Thanks for the info.

[J. Jones]

I am interested in welding to convert a 4 door car into a limousine. I would like to know if the Lincoln Electric SP180 model would work for this project? Thank You, for your information on the show.

[Ian]

Phosgene gas comes from exposing tetrachloroethylene (or any refrigerant)to heat in excess of about 1000F. Call me crazy, but shouldn't the risk be eliminated if the cleaner has all evaporated? The refrigerant is only used as a propellant (which is a big part of why it is so cold when you spray it...) and is mostly in gas form when sprayed...been working with freon for ten years, but surely I don't know everything. And as a heads up for any smokers...it doesn't tell you not to smoke around the stuff just because it is flammable...that cherry on your cigarette will also exceed 1000F, giving the phosgene gas a straight shot to your lungs!!

[Pratik]

Hi,

My name is Pratik; I'm a Web Associate for ThomasNet.com. I came across your site and I notice you make mention of welding related articles.

ThomasNet recently launched a large information base at http://www.thomasnet.com/articles/custom-manufacturing-fabricating, and we have a specific article(s) that I thought you could make use of.

If you have a moment, could you please review the article and see if it's worthy of a mention on your site as an additional resource for your users?

Thanks so much for your time. Hope to hear soon from your end.

Best Regards,

Pratik
pmaru@thomasnet.com

[don]

Thanks good tip ...what respirator will fit under your welding helmet????..hmm maybe bout time someone makes one HMMMMM??
HAPPY NEW YEAR TO ALL!!2011

[Zoey Schmucker]

There are times when you're going to have this urge to modify your used car. Well, given that you're the type who actually does mods for autos. Now that you've mentioned something about the science involved in welding, they'll know what they should do to avoid these harmful elements.

[dental hygiene continuing education]

What are the symptoms of Crohn, why this disease is dangerous and how can we get this cured, I need info about this, I read the other bloggers suffering and it was really scary.

[Adam Preece]

Welding cars should always be done thoroughly. Plus, having the skill gives you the chance to do your own modifications to your car. It helps in repairs, too! But it can be risky if you're not an experienced welder.