焊接烟尘会对健康造成多种威胁，包括金属烟雾热病、神经系统问题、肺病和癌症。幸运的是，配有合适的除尘器的焊烟抽排系统可以去除焊接烟尘中的大部分有害成分。无论是源头抽排系统还是环境空气过滤系统，选择合适的焊烟除尘器对于有效捕获焊烟中的微小颗粒（通常为亚微米级）至关重要。影响焊烟除尘器选择的因素有很多，包括焊接应用、操作环境等。

　　Welding fumes can pose various threats to health, including metal smoke fever, neurological problems, lung disease, and cancer. Fortunately, a welding smoke exhaust system equipped with a suitable dust collector can remove most of the harmful components in welding fumes. Whether it is a source exhaust system or an ambient air filtration system, choosing the appropriate welding smoke dust collector is crucial for effectively capturing small particles (usually in the sub micron range) in welding smoke. There are many factors that affect the selection of welding smoke dust collectors, including welding applications, operating environments, etc.

　　焊工的除尘基础知识美国职业安全与健康管理局（OSHA）对焊接烟尘的总接触量以及某些焊接烟尘中的个别成分（如六价铬和锰）设定了允许接触限值（PEL）。为达到焊接烟尘 PEL 标准并确保焊工安全，采用了使用焊接烟尘除尘器的烟尘收集系统。焊接烟尘收集系统包括：

　　The US Occupational Safety and Health Administration (OSHA) has set permissible exposure limits (PEL) for the total exposure to welding fumes and certain individual components in welding fumes, such as hexavalent chromium and manganese. To meet the PEL standard for welding fumes and ensure the safety of welders, a smoke collection system using a welding fume dust collector was adopted. The welding fume collection system includes:

　　● 带过滤单元的固定式或便携式除尘器● 通过管道连接到除尘器的吸气罩/系统，如封闭式吸气罩（用于机器人焊接）或吸气臂、环保焊枪

　　● Fixed or portable dust collectors with filtering units ● Suction hoods/systems connected to the dust collector through pipelines, such as enclosed suction hoods (for robot welding) or suction arms, environmentally friendly welding guns

　　除尘器将焊接烟尘吸入过滤腔体（或者在安装袋式除尘器的时候吸入滤袋），焊接烟雾中的污染物被捕获在过滤介质中。过滤后的清洁空气可返回工厂或排放到室外。滤筒除尘器广泛应用于许多焊接应用较普遍的行业，因为它们是捕捉与焊接有关的危险烟气的有效方法。这些除尘器使用圆柱形褶皱滤筒。与袋式除尘器相比，这种褶式设计能在更紧凑的空间里提供更大的过滤面积。

　　The dust collector sucks welding fumes into the filtering chamber (or into the filter bag when installing a bag filter), and pollutants in the welding fumes are captured in the filtering medium. The filtered clean air can be returned to the factory or discharged outdoors. Filter cartridge dust collectors are widely used in many industries where welding applications are common, as they are an effective method for capturing hazardous fumes related to welding. These dust collectors use cylindrical pleated filter cartridges. Compared to bag filters, this pleated design can provide a larger filtration area in a more compact space.

　　什么是滤筒式除尘器？任何除尘系统的重点都是用于过滤有害污染物的滤材。滤筒除尘器的滤材通常呈圆柱形，由过滤介质、滤筒外壳和端盖组成。过滤介质通常为褶皱状，以便在更小的空间内提供更大的烟尘收集面积。筒式除尘器的尺寸和配置各不相同，以适应不同制造商设计的过滤系统。用于焊接烟尘的筒式除尘器有不同的过滤介质类型（包括纤维素、聚酯和混合材料）和涂层选项（如纳米纤维或聚四氟乙烯）。

　　What is a filter cartridge dust collector The focus of any dust removal system is on the filter material used to filter harmful pollutants. The filter material of a filter cartridge dust collector is usually cylindrical, consisting of a filter medium, a filter cartridge housing, and an end cap. The filter medium is usually wrinkled to provide a larger smoke and dust collection area in a smaller space. The size and configuration of cylindrical dust collectors vary to accommodate filtration systems designed by different manufacturers. The cylindrical dust collector used for welding fumes has different types of filter media (including cellulose, polyester, and mixed materials) and coating options (such as nanofibers or polytetrafluoroethylene).

　　了解过滤效率过滤效率是指除尘器在空气通过过滤介质时捕获各种大小颗粒的能力。

　　Understanding filtration efficiency refers to the ability of a dust collector to capture particles of various sizes when air passes through a filtering medium.

　　● 大多数用于捕捉焊接烟尘的滤筒都采用最低效率报告值 (MERV) 系统进行评级，该系统的效率范围从 1 到 16 ，其中 16 为最高效率。MERV 评级基于三个不同尺寸范围的颗粒物收集百分比：3-10 微米、1-3 微米或 0.3-1 微米。MERV 15 滤芯至少能收集 85% 的 0.3-1 微米范围内的颗粒，而 MERV 16 滤芯则能收集 95% 的此类颗粒。● HEPA滤筒的过滤效率超过 MERV-16 滤芯，可捕捉 99.97% 的 0.3 微米或更大的颗粒。

　　Most filter cartridges used to capture welding fumes are rated using the Minimum Efficiency Reporting Value (MERV) system, which ranges in efficiency from 1 to 16, with 16 being the highest efficiency. The MERV rating is based on the percentage of particulate matter collected in three different size ranges: 3-10 microns, 1-3 microns, or 0.3-1 microns. The MERV 15 filter can collect at least 85% of particles within the range of 0.3-1 microns, while the MERV 16 filter can collect 95% of such particles. The filtration efficiency of HEPA filter cartridges exceeds that of MERV-16 filters, capturing 99.97% of particles 0.3 microns or larger.

　　过滤介质类型除尘器由不同类型的介质组成，适用于不同的环境和工业用途。常见的滤材类型包括：

　　Filter media type: Dust collectors are composed of different types of media and are suitable for different environments and industrial applications. Common types of filter materials include:

　　● 纤维素：一种多功能介质，适用于轻型和一般用途，用于收集干燥颗粒。

　　Cellulose: a multifunctional medium suitable for light and general use, used for collecting dry particles.

　　●纤维素/聚酯混纺：专为高湿度环境设计，可捕捉潮湿粉尘和较重的粉尘负荷。

　　● Cellulose/polyester blend: designed specifically for high humidity environments, capable of capturing damp dust and heavy dust loads.

　　●纺粘聚酯：无纺布纤维/连续长丝聚酯纤维使这种滤材耐化学腐蚀。它还能在高温和具有挑战性的工业环境中使用。

　　● Spunbond polyester: Non woven fibers/continuous filament polyester fibers make this filter material resistant to chemical corrosion. It can also be used in high temperature and challenging industrial environments.

　　●纳米纤维：这种滤材在另一种基材（通常是聚酯或混纺材料）上覆盖一层纳米纤维（非常细的纤维）。纳米纤维层使这些滤材能更好地捕捉亚微米颗粒，如焊接烟尘中的颗粒。

　　● Nanofiber: This filter material is covered with a layer of nanofibers (very fine fibers) on another substrate (usually polyester or blended material). The nanofiber layer enables these filter materials to better capture submicron particles, such as those in welding fumes.

　　●聚四氟乙烯涂层（PTFE）：这些滤材的基材上有一层薄薄的聚四氟乙烯覆膜，可提供很高的过滤效率和出色的防潮、防化学腐蚀和耐磨性能。常用于颗粒潮湿、油性、粘性或磨蚀性的情况。

　　● Polytetrafluoroethylene coating (PTFE): These filter materials have a thin layer of PTFE film on their substrate, which provides high filtration efficiency and excellent moisture resistance, chemical corrosion resistance, and wear resistance. Commonly used in situations where particles are moist, oily, viscous, or abrasive.

　　●疏油介质：这种过滤介质可排斥油和其他疏水性物质。

　　● Oil repellent medium: This type of filter medium can repel oil and other hydrophobic substances.

　　选择合适的焊接烟尘滤材

　　Choose the appropriate welding smoke filter material

　　大多数企业在选择合适的焊接烟尘除尘器时，首先要了解与其特定类型焊接中产生的颗粒相关的 PEL 值。每个焊接过程都会产生不同浓度的有毒颗粒，了解这种烟尘负荷可以为焊接烟尘滤材的决策提供依据。

　　Most companies first need to understand the PEL value related to the particles generated during their specific type of welding when choosing a suitable welding dust collector. Each welding process produces different concentrations of toxic particles, and understanding this smoke load can provide a basis for decision-making on welding smoke filter materials.

　　另一个因素是其他类型的工业生产过程会向空气中引入不同的微粒。焊接烟尘会产生干性颗粒，因此，如果在除尘系统中也过滤了焊接应用之外产生的湿性/油性/粘性物质，则需要在选择除尘器时将其输入到公式中。

　　Another factor is that other types of industrial production processes introduce different particles into the air. Welding fumes can produce dry particles, therefore, if wet/oily/viscous substances generated outside of welding applications are also filtered in the dust removal system, they need to be input into the formula when selecting the dust collector.

　　焊接烟尘特性和过滤效率

　　Characteristics and filtration efficiency of welding fumes

　　抽排焊接烟尘的最大挑战之一是所涉及的颗粒非常小，大多数颗粒都在亚微米范围内。当金属在焊接的高热过程中气化时，气相分离的颗粒会传播到空气中。这些有害物质很容易被人吸入肺部，并对健康构成严重威胁。

　　One of the biggest challenges in extracting welding fumes is that the particles involved are very small, with most particles in the submicron range. When the metal vaporizes during the high heat process of welding, the particles separated by the gas phase will spread into the air. These harmful substances are easily inhaled into the lungs and pose a serious threat to health.

　　美国职业安全与健康管理局（OSHA）根据八小时轮班的时间加权平均接触量设定了接触限值（PEL）。在焊接低碳钢、铁或铝时，PEL 为 5 毫克/立方米。不过，OSHA 还为焊接烟尘中的个别化合物和元素设定了 PEL 值。

　　The Occupational Safety and Health Administration (OSHA) in the United States has set exposure limits (PELs) based on the time weighted average exposure of an eight hour shift. When welding low carbon steel, iron or aluminum, the PEL is 5 milligrams per cubic meter. However, OSHA has also set PEL values for individual compounds and elements in welding fumes.

　　● 焊接烟尘中毒性最强的物质之一是六价铬，它具有剧毒，是不锈钢和其他高铬合金焊接中的致癌物质。(PEL：每立方米 5 微克）。

　　One of the most toxic substances in welding fumes is hexavalent chromium, which is highly toxic and carcinogenic in the welding of stainless steel and other high chromium alloys. (PEL: 5 micrograms per cubic meter).

　　●填充材料和焊料中的镉可导致肺癌。(PEL：每立方米 5 微克）。

　　● Cadmium in filling materials and solder can cause lung cancer. (PEL: 5 micrograms per cubic meter).

　　●即使是少量的铍也会导致肺癌。(PEL：0.2 微克/立方米）。

　　● Even a small amount of beryllium can cause lung cancer. (PEL: 0.2 micrograms per cubic meter).

　　●焊接烟尘中通常还含有铅、锰、镍、铝和砷，这些物质会导致一系列问题，从金属烟雾热病到呼吸系统问题，再到严重的神经损伤和癌症。(PEL值不同）。

　　● Welding fumes often contain lead, manganese, nickel, aluminum, and arsenic, which can cause a range of problems, from metal smoke fever to respiratory problems, to severe nerve damage and cancer. (PEL values vary).

　　鉴于焊接烟尘中的颗粒尺寸为亚微米级，通常需要使用 MERV 等级（MERV 15 或 16）较高的滤材，以符合 PEL 标准，尤其是六价铬、镉和铍等毒性较高的物质。所有筒式除尘器都会在负荷增加并形成尘饼后接近 MERV 16 的效率水平。不过，在处理剧毒烟雾时，必须首先使用初始效率足够高的滤材，以便在新除尘器投入使用时为焊工提供保护。一般焊接工作通常不需要 HEPA滤筒，但在使用 PEL 值较低的剧毒物质时，建议使用 HEPA 滤筒。

　　Given that the particle size in welding fumes is sub micron, it is usually necessary to use filter materials with a higher MERV rating (MERV 15 or 16) to comply with PEL standards, especially for highly toxic substances such as hexavalent chromium, cadmium, and beryllium. All cylindrical dust collectors will approach the efficiency level of MERV 16 after increasing the load and forming a dust cake. However, when dealing with highly toxic smoke, it is necessary to first use filter materials with sufficient initial efficiency to provide protection for welders when new dust collectors are put into use. Generally, welding work does not require HEPA filters, but when using highly toxic substances with lower PEL values, it is recommended to use HEPA filters.

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