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Safety In Engineering Industry >Chapter 1> Topic – Hazards at Workplace > Subtopic- Welding and Gas Cutting ,Brazing , Soldering , Polishing and Buffing hazards and their Preventive measures

 Welding and Gas Cutting ,Brazing , Soldering , Polishing and Buffing hazards and their Preventive measures

Welding and Gas Cutting - 



A welding is defined as local coalescence of metal wherein coalescence is produced by heating to suitable temp. with or without application of pressure and with or without use of filler metal.

There are many types of welding processes where the gases, sand, filler wires, electrodes, fixtures, cylinders, chemicals involved. -which affects on working condition , health of workers, environment.

The welding process has many types of hazards involved like chemical hazard, fire hazard, mechanical hazard, electric hazard. 





Gas Welding Videos for reference :  https://www.youtube.com/watch?v=-SA4D098u-Q

Following are hazards involved in welding process as well as in the Gas Cutting:

1. Flying metallic sparks and molten metal. Some of these sparks consist of tiny shreds of extremely hot metal, sometimes molten metal, which may be hotter than 1000°F and may cause painful burns on skin. These sparks are also source of fire or explosion hazard in case flammable materials are nearby.

2. Burn injury may happen due to hot surfaces of work pieces after welding.

3. Flying materials while chipping the weld.

4. Poisonous gases.

5. Enrichment of oxygen which affects or enhances the flammability.

6. Glare which comes when arc is struck, or the torch is lit. It affects the optic nerve at the back of eye.

7. Heat radiation from welding can cause headache, fatigue and eye damage.

8. Infrared Radiation. Some of the IR is stopped by the upper layer of skin but part of radiation penetrates to the exposed skin and may cause serious skin burns or pigmentation. Eye has no upper layer, it can affect the eye which may cause “heat cataract”

9. Ultra-violet radiation may cause skin burns and prolonged exposure may lead to skin cancer.

10. Workers on the shop floors may exposed to noise due to welding, cutting or chipping operations.

11. Fall of materials and equipment during operation. 

12. Electric shock due to involvement of electric current in every welding. 

Brazing

In Brazing, the coalescence between metallic parts is obtained by,

1. Heating them to suitable temperature.

2. Using filler metal with melting point above 450°C, below melting point of base metal.

3. Heating the filler metal till it melts and gets distributed between closely filled surface by capillary action.

 


Types of Brazing : Resistance brazing, Dip brazing, Flame brazing, Diffusion brazing, etc 

Brazing is commonly use for- Producing bicycle parts, Heat exchanger, Aerospace structure, Automobile radiators.

 Brazing Video for reference : https://www.youtube.com/watch?v=zbqsmvKk2Sk

Hazards in Brazing:

1. Electric shock.

2. Burn injury.

3. Eye damage / injury

4. Cuts injury

5. Crushed toes and fingers.

6. Exposures to fumes and gases.

7. Heat stress and cold stress during welding.

 

Preventive measures:

1. Proper use of PPE’s.

2. Use the properly maintained and approved apparatus.

3. Operator should insulate properly.

4. Portable fire extinguisher should be available.

5. Brazing area should be free from flammable substances.

6. Ensure shielding of material which cannot be moved. 


Soldering

Soldering is done for electronic equipment like panel, circuits, and windings work etc. 




Hazards in Soldering:

1. Shock – electric shock due to use of bad quality cables- joints in cable.

2. Burn Injury- Due to miss handling of hot soldering gun.

3. Inhalation of lead fumes.

4. Fire hazard due to hot gun contact with flammable substances.

5. Ingestion of lead through skin.

6. Use of fluxes without ventilation.

7. Inadequate cleaning of surfaces in the work area.

 Soldering Video for Reference - https://www.youtube.com/watch?v=cd3vn8GsmzA 

Preventive measures for soldering operation :

1. Soldering gun should be of good quality.

2. Proper electrical connections. Soldering wire should be free from joints, cuts.

3. Stand should be provided to keep the hot gun safely.

4. Turn off or unplug the gun when not in use.

5. Conduct the work in well ventilated area.

6. Avoid breathing of lead fumes by keeping head aside.

7. Always wash your hands with soap after operation.

8. Use lead free or low lead solder wherever possible.

9. Keep fire extinguisher in reachable area.

10. Wear nonflammable cotton clothes.

11. Examine equipment before use.

12. Safety glasses and gloves should be used.

 

Polishing and Buffing

Polishing and Buffing both are the surface finishing methods.

Polishing Operation 


Hazards in Polishing and Buffing:

1. Entanglement of hair and clothing into the spindle, mop or brush.

2. Ejected work pieces, wires from brushes and particles from polishing process can be ejected form machine

3. Hot work pieces can cause burns.

4. Electric shock.

5. Sharp edges can cause cuts.

6.  In advert starting of machine.

7. Inhalation of dust.

8. Lack of space around the machine can lead to the operator being pushed by passers by

9. Falling on slippery floor.

 

Buffing Operation


Preventive measures for Polishing and Buffing:

1. Proper selection of machine with properly maintained equipment.

2. Gloves should not be worn when using machine.

3. long hair, jewelry should be properly tied.

4. Suitable eye protector should be used.

5. Guarding and proper insulation should be provided.

6. Room ventilation should be adequate.

7. Enough space should be available around the machine

8. Floor space should not be slippery and should be free from loose items.

9. machine should not be unattended and powered when not in use.

 

Polishing Video For reference : https://www.youtube.com/watch?v=Pkm-ft2NI5c

Buffing Video for reference : https://www.youtube.com/watch?v=k1Ng9RhSstE

 

Reference : 

Images : Google.com
Video Links - YouTube 
Books : NSO Notes  
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