The GMAW (MIG /MAG) process is widespread in industry. However, it presents limitations regarding metallurgical aspects and geometrical characteristics of the weld bead. The FCAW process, on the other hand, due to presence of fluxes, achieves improvements on these aspects, but the flux might be responsible for larger fume emission. This paper aimed to present a comparative study of fume generation between the GMAW process with short-circuit metal transfer and the gas shielded FCAW process, using wires of same class of resistance (483 MPa of ultimate tension) and application. The experiments were performed in a fume chamber calibrated according to a standard. Both wires were evaluated using 100% CO2 as the shielding gas and at two current levels. The arc length effect and the use of another shielding gas (25% CO2 in argon) were also evaluated. Appropriate conditions of contact-tip-to-work-piece distance and arc voltage were selected for each wire-shielding gas combination as a means of making the comparison closer to the reality. The volume of the weld beads per meter was made the same for each level of current, by keeping the same relationship between wire deposition and welding travel speed. The results confirm a higher fume generation rate of the FCAW process (already expected) and that absolute fume generation rate grows as the welding current increases. However, for the GMAW process, analyzed from a relative point of view, it doesn't happen. It was verified that the current effect is more significant on the FCAW process. The increase in the CO2 content raised the fume generation rate only for the FCAW process, whilst the arc voltage variation did not demonstrate any effect on it.
Fumes; GMAW; FCAW; tubular wire; gas shielding
