Welding is the most efficient and eco welding and the most commonly welded
nomical means of permanently joining metal is mild steel; this accounts for near
metals; it provides design flexibility and ly 90% of all welding in the United States.
lighter weight through better utilization Arc welding is a method of fusing metals
of materials. Welding can join all com with the heat of an electric arc (about
mercially used metals. 3,870 C). Currents vary from 25 to 1,000
The U.S. Department of Labor 1970 amps, depending upon the thickness of
census data reported that there are nearly the metal. Filler metal, which is usually
500,000 welders and flame cutters in the added, melts and mixes with the molten
United States, working primarily in main base metal to form weld metal.
tenance and repair. 1 Process shielding of some type is used
There are nearly 60 different types of in most arc welding and is necessary to
welding (including forge welding, arc produce high-strength welds. Shielding
welding, gas welding, resistance welding, protects the molten metal from contami
spot or seam welding, aluminothermic nation by atmospheric oxygen and nitro
welding, ultrasonic welding, plasma-arc gen. Gases, molten slag, or both are used
welding, and electron-beam welding) in as shields.
use. The most widely employed is arc Safety and medical problems in weld-
ingThe medical and safety problems
From the Department of Ophthalmology, Univer
associated with welding include welder's
sity of Louisville School of Medicine, Louisville, flash (actinic keratitis), skin burns, for
Kentucky. eign objects in the eye, fume inhalation,
Reprint requests to Arthur H. Keeney, M.D., electric shock, overheating, injuries re
Department of Ophthalmology, University of Louis
ville School of Medicine, 301 E. Muhammad Ali sulting from explosion of fire, and death.
Blvd., Louisville, KY 40202. All conventional welding processes pro-
AMERICAN JOURNAL OF OPHTHALMOLOGY 92:77-84, 1981 77
78 AMERICAN JOURNAL OF OPHTHALMOLOGY JULY, 1981
was attained or when the temperature tape, reflective side facing the plate, was
became too high for the welder to contin- placed over the thermocouple junction to
ue. Such conditions apply in actual work, minimize heat loss. Duct tape held the
The protocol sheet used for each weld- thermocouple and aluminum tape to the
ing run is shown in the Figure. plate. A 10 X 10 X 3-mm piece of Styro-
MeasurementsWe mounted welding foam was attached over the duct tape to
filter plates on two new welding helmets. minimize environmental interference.
A front cover plate and a back safety We connected thermocouple leads to a
plate, each of allyl resin (CR-39) 1.3 to strip recorder equipped with two pens to
1.45 mm thick, were used in all cases record the temperature of the two plates
except when the temperature of the simultaneously and continuously. Verifi-
welding plate itself was being monitored; cation temperature readings were ob-
the back safety plate was omitted in that tained by test immersions alternately in
instance. boiling water and in ice and water. We
Iron-constantan thermocouples were used an additional iron-constantan ther-
attached to the back safety plate with a mocouple to verify further the recorded
small amount of Type 29 heat sink com- temperatures.
pound designed to conduct heat but not Each of two helmets was fixed to a
electricity. A 1-cm square of aluminum tripod, equidistant at the usual working
RESULTS
Figure (Pabley and Keeney). The protocol sheet used for the welding tests.
80 AMERICAN JOURNAL OF OPHTHALMOLOGY JULY, 1981
distance from the welding site; filter polycarbonate filter plates thus reduced
plates facing the welding were angulated the rise in plate temperature above the
at approximately 55 degrees from the ambient 162%.
vertical. This is an optimum viewing After this experiment, the front of the
angle and simulates a welder's position glass plates showed extensive pitting
during work.4,5 caused by spatter but the gold reflective
There is no single optimal working polycarbonate filters showed no spatter
distance for welders. We surveyed the marks.
distances used in two different shops. With both front and back safety plates
These varied from 6 to 20 inches depend in place (the recommended practice
ing upon the process, vision, and age of which, however, is not always followed),
the welder. A welder who does not have the reduction in temperature with poly
presbyopia tends to use a distance closer carbonate reflective plates was less
than the conventional reading distance of marked and ranged from 10% for gas
13 to 15 inches. Therefore, we fixed the metal-arc welding to 30% for carbon-arc
welding helmets at distances ranging gouging.
from 9 to 15 inches from the workpiece.
DISCUSSION
RESULTS
Welding and radiationThe intensity
In each process studied, green glass- and spectrum of welding arcs depend on
welding filters attained higher tempera the following factors: (1) the type of pro
tures than the polycarbonate-reflective cess, (2) the length of the arc, (3) the
filters (Table). In shielded metal-arc or atmosphere and shielding about the arc,
stick welding (the most widely used proc (4) the level of welding current, and
ess) without front or back safety plates, (5) climatic and other minor variables.
gold reflective polycarbonate filter plate Smoke produced in some welding acts as
produced a marked reduction in tempera a filter, reducing luminous and ultraviolet
ture. In this process the plate tempera intensities. The unstable temperatures of
ture rose 216% above the ambient with the arcs and the variations in the heating
the green glass plates and 54% with the of the metals pose major problems in the
polycarbonate reflective filter plates. The quantitative study of welding radiations.
TABLE
R E D U C T I O N IN W E L D I N G F I L T E R PLATE TEMPERATURE RISE ABOVE AMBIENT W I T H POLYCARBONATE
R E F L E C T I V E PLATES COMPARED T O ABSORPTIVE GREEN GLASS
Slight changes in arc are also caused by which is also absorbed primarily in the
the continuous melting of the electrodes, retinal pigment epithelium. Energy ab
making it difficult for the welders to keep sorbed in the retinal pigment epithelium
a constant arc length. Molten metal can cause thermal coagulation injury or
breaking off from the electrode causes destruction of retinal cells. Localized
fluctuation. Also, drafts or shifts in air lenticular opacities progressing to signifi
currents are frequent variables. cant cataracts have been produced exper
Zaborski 6 suggested that energy distri imentally by several investigators using
bution in the arc spectrum does not re large doses of filtered infrared. These are
semble the spectrum of a full radiator or associated with denaturation of lens pro
that of solar radiation with a slight shift of teins. Infrared above 1,400 nm is ab
the maximum toward long waves. Zabor sorbed by the cornea and aqueous; at
ski noted that: levels beyond 1,900 nm, the cornea ab
sorbs all of it. Long-term repeated expo
The spectrum of a welding arc is complex, consist sures to near-infrared at levels far below
ing of a temperature spectrum, plus overlapping
line and band spectra from the vapours of melted the threshold for acute injury, although
metal, from the elements and compounds leaving apparently not hazardous to the retina,
the covering of the electrode or the gaseous enve may damage the lens. Data on experi
lope and entering die arc.
mental laser injuries 5 have suggested that
Sutter and associates 7 published the a safe level for long-term infrared expo
results of a German study on radiation sure is an average ocular irradiance of
measurements in various arc processes. approximately 0.01 W/cm 2 . Hubner, Sut
Zaborski studied the visible spectrum of ter, and Wicke 9 measured infrared emis
the welding arc. One of the most exten sions as high as 0.34 W/cm 2 in some
sive studies was done jointly by the welding processes.
American Welding Society and the U.S. Visible radiation (400 to 700 nm) is
Army. 5,8 Their data showed that the radia focused by the optical system of the eye
tion intensity of the four processes in and, depending upon the incident inten
creased from the lowest, plasma arc weld sity, can cause retinal burns with perma
ing, to gas tungsten-arc welding and nent cell loss and impairment of vision.
shielded metal-arc welding, and finally to None of the anterior structures of the eye
the highest, gas metal-arc welding. absorbs a significant amount of visible
Biologic effects of welding radiation radiation except the iris, 10 which is pig-
Different adverse biologic effects stem mented posteriorly and heavily vascular-
from visible light, near- and far-infrared, ized. The high level of blood circulation
and the three (A, B, and C) divisions enables it to absorb intense visible light
of ultraviolet. Welder's flash keratitis without suffering a significant increase in
(photokeratitis) has been known since the temperature. The retina, however, has a
1880s. very low threshold for visible light dam
The main ocular hazards from infra age. The type of retinal damage depends
red are thermal. Near-infrared (700 to upon wave length, energy level, duration
1,400 nm), to which the cornea is trans of exposure, and pigmentation character
parent, is absorbed by other anterior istics. Ham and associates 11 have shown
structures, chiefly the lens. Only a small that the retina is most susceptible to
fraction of incident near-infrared reaches photochemical damage from short-
the retina where it is absorbed in the wavelength visible light (400 to 580 nm),
retinal pigment epithelium. The amount even at energy levels too low to produce a
is small in comparison to visible light, significant temperature rise. High energy
82 AMERICAN JOURNAL OF OPHTHALMOLOGY JULY, 1981
levels increase temperatures in the reti "Practice for Occupational and Educa
nal pigment epithelium and choroid, re tional Eye and Face Protection."
sulting in thermal denaturation of cells in The light-absorbing properties of a fil
the retinal pigment epithelium and the ter lens can be expressed in terms of a log
sensory retina. The photochemical lesion function, optical density. National Bu
is markedly wavelength-dependent. Reti reau of Standards shade numbers are de
nal sensitivity increases sharply in the rived from density.
blue-violet range.
The so-called blue-light hazard has Optical density =
been studied carefully in recent years. 1
Standards for ocular protection in weld / transmitted \ / incident \
ing may have to be reevaluated for this \ energy j [ energy J
component of visible light alone and for
its effect with near-infrared. Zaborski, 6 Optical densities of nonreflective lenses
studying the visible spectrum of the are linearly related to thickness when the
welding arc, noted that the maximum dye or absorptive compound is uniformly
energy level is usually within 420 to distributed through the material. Trans-
430 nm. According to Ham and associ mittance, the inverse of optical density,
ates, 11 the photochemical hazard predom equals 10~d where d is the optical density
inates over the thermal one when the of the filter.
spectrum contains significant amounts of
blue light. They found that producing a Shade No. = ( | ) d + 1
minimal lesion with near-infrared radia
tion (1,064 nm) required energy at the Thus, transmission is less as optical den
corneal level three orders of magnitude sity or shade numbers increase; for ex
greater than producing a minimal lesion ample, shade 2, with an optical density
with blue light (441.6 nm) did. Radiation of 0.429, is useful for torch soldering
at 1,064 nm also causes high tempera and shades 2 to 5 for spot welding, where
tures and thermal damage in the retina, as shade 14, with an optical density of
but 441.6-nm light produces negligible 5.571, is extremely dense and is used
increments in retinal temperature at the for welding processes such as carbon-
energy levels required to produce a reti arc welding that emit intense optical radi
nal lesion. Extended exposures, even at ation.
low levels of radiation, may create cumu From the 1880s until recent years, the
lative photochemical damage. mainstays of protection from welding-arc
Protective eyewear in weldingThe radiation were thick filter plates of glass.
main functions of filter plates used in In 1914, ferrous oxide (Sir William
welding are (1) the reduction of harmful Crookes' sage-green glass, No. 217) was
ultraviolet, visible, and infrared radia added as an infrared absorber. Although
tion, (2) the mechanical protection of the allyl diglycol carbonate plastic lenses
welder's eye, particularly from weld spat were introduced in 1942, it was not until
ter, and (3) the reduction of visible light 1968 that polycarbonate filter plates were
to a comfortable level to improve visibili introduced. This impact-resistant plastic
ty in the welding zone. meets all applicable standards, although
In the United States, filter lenses or its surface is considerably softer and its
plates used in welding must meet re index of refraction (1.58) slightly higher
quirements set by the American National than that of allyl resin. Initial attempts to
Standards Institute Standard Z87.1-1979, coat plastic lenses were unsuccessful. In
VOL. 92, NO. 1 OCULAR HAZARDS OF WELDING 83
Welding Methods. Optical Report 2/72. Braun 11. Ham, W. T., Mueller, H. A., Ruffolo, H. H.,
schweig, West Germany, Laboratory for Spectrosco- and Clarke, A. M.: Sensitivity of the retina to radia
py, 1972. tion damage as a function of wavelength. Photochem.
8. Hinrichs, J. F.: Safety and Health. Project Photobiol. 29:735, 1979.
Committee on Radiation. Summary Report. Welding 12. Kors, K., and Peters, H. B.: Absorption char
J. 57:62, 1978. acteristics of selected commercially available oph
9. Hubner, H. J., Sutter, E., and Wicke, K.: thalmic lenses. Am. J. Optom. Arch. Am. Acad.
Measurement of radiation power at welding proc Optom. 49:727, 1972.
esses and consequences for eye protection against IR 13. Duke-Elder, S., and MacFaul, P. A.: Injuries.
radiation. Optik 31:462, 1970. Non-Mechanical Injuries. In Duke-Elder, S. (ed.):
10. Wolbarsht, M. L. : The effects of optical radia System of Ophthalmology, vol. 14, pt. 2. St. Louis,
tion on the anterior structures of the eye. In Ten- C. V. Mosby, 1972, p. 882.
groth, B. (ed.): Current Concepts in Ergophthalmol- 14. Sherr, A. E.: Glasses, shields protect eyes
ogy. Stockholm, Societas Ergophalmalogica Interna- from shop hazards. Welding Design Fabrication,
tionalis, 1978, pp. 29-49. 53:140, 1980.
OPHTHALMIC MINIATURE