745 Welding, Cutting, and Brazing Safety

Top 10 Chemical Exposures

2. Cadmium (Cd)

Cadmium is a soft, bluish-white metal that is primarily used in various industrial processes, including welding and brazing. In welding, cadmium can be found in certain filler materials, coatings, and alloys—particularly cadmium-bearing silver solders or plated metals. It is sometimes used for its corrosion resistance and ease of joining metals.

Exposure Risks: Cadmium presents serious health risks, especially when it is heated. Welding or cutting materials that contain cadmium can release highly toxic fumes and dust. These fumes are easily inhaled and rapidly absorbed into the lungs, where they can cause both acute and chronic health effects.

Health Effects: Short-term or acute exposure to cadmium fumes can lead to severe respiratory irritation, including symptoms like coughing, chest pain, and shortness of breath. In more serious cases, it can cause chemical pneumonitis and pulmonary edema, which can be fatal. Chronic exposure, even at low levels over time, is associated with long-term damage to the lungs and kidneys. Cadmium is also classified as a known human carcinogen, linked to lung cancer through inhalation exposure.

Because of these risks, cadmium-containing materials require strict control measures during welding operations, including adequate ventilation, proper respiratory protection, and careful handling of contaminated surfaces and waste. Training and awareness are essential for protecting workers from cadmium-related hazards.

3. Beryllium (Be)

Beryllium is a lightweight, strong metal known for its high thermal conductivity, stiffness, and resistance to corrosion.

It is often alloyed with other metals, such as copper, to enhance electrical and mechanical properties. In welding, beryllium is typically encountered in the form of beryllium-copper alloys, which are used in aerospace, electronics, precision tools, and high-performance components because of their strength and conductivity.

Exposure Risks: The primary hazard associated with beryllium exposure occurs when it becomes airborne as dust, fume, or vapor during welding, grinding, cutting, or other thermal processes. Inhalation of these airborne particles can cause serious health effects.

Health Effects: The most significant long-term risk is chronic beryllium disease (CBD), a potentially debilitating and incurable lung condition that can develop after a person becomes sensitized and inhales beryllium. However, acute beryllium disease is also possible after high short-term exposure and can resemble pneumonia. In addition, long-term exposure to beryllium has been linked to lung cancer, and skin contact can cause rashes or lead to sensitization.

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