Fume Extraction Should Do More Than Capture Weld Fumes.
It Should Actually Protect Your People.
Fume extraction solutions should focus first on your people.
That's why our solutions capture fumes at the source and keep them from spreading to your workforce.
What is Fume Extraction?
Why Do I Need Fume Extraction?
Our guiding belief is that source capture fume extraction is the most effective means to limit weld fume exposure and protect your most valued asset: your people.
Source capture means that the weld fume is caught at the welding arc and filtered into a nearby fume extraction system. This limits the fumes ability to spread to other parts of the plant and expose workers.
This allows your plant to be cleaner, safer, and more productive in the end.
We emphasize the following within our fume extraction products:
High Static Pressure
Fume extraction systems use either high or low static pressure in their solutions.
High static pressure allow for solutions to be closer to the weld arc and catch higher concentrations of welding fume to limit the spread.
This is critical when welding at higher parameters, as the concentration of metal particulate is heavier as your weld power increases.
High static pressure keeps air from entering not just the breathing zone of the welder, but also from spreading to other parts of the plant and exposing other people on the shop floor.
We believe this is the most effective way to capture weld fumes, and design our fume extraction tools to work in this way.
If your equipment is not easy to use, then it will be less efficient.
Everything from our fume extraction welding guns to our multi-station fume systems are made to be easy to operate and maintain using a minimal number of tools and using easy to check signals if a system is in need of maintenance.
In the past, the reputation of fume extraction welding guns was that they are heavy, bulky, and low performing in nature.
Today's fume extraction welding guns are just the opposite. They are made far lighter, are more ergonomic, and capture much more welding fume when paired with the right vacuum system.
Fume extraction systems of the past were also weaker and lacked modern technological advances.
Our systems today self-clean and use automatic start/stop features to save on energy costs and lessen wear and tear.
Welding Tool First
The most important function of a fume extraction solution is to not compromise the ability to weld.
We apply the same principles to our fume extraction solutions as we do our welding torches.
They are designed to improve welding production and capability and never take away from it.
Fume extraction torches from ABICOR BINZEL are made with the same attention to detail and use the same high quality, precision-machined consumabels as other BINZEL welding guns.
Features like swivel hoses, comfortable handle, and optimal triggers keep the welding tool comfortable to use so welders stay productive on the job.
We offer fume extraction solutions for manual and robotic welding applications. These solutions are designed to capture weld smoke right at the weld arc.
Depending on the processes used, the material in question, or the size of the part, the best fit for your fume extraction needs may vary.
Capture Fumes Where They Start and Not Where They Go
- We care about protecting more than your welders
- While your welders need protection, they also need to comfortably perform
- Tailored torch configurations to match your production needs
- All sorts of source capture options depending on weld positions
- Cost-effective and safety forward
The Old Ways of Robotic Fume Extraction Have Changed
- Far more cost-efficient and flexible than hood or general ventiliation systems
- More effective at capturing fumes right where they start
- Easy to install and maintain
- Doesn't keep your robot from performing
- Extract fume on larger parts than can't be enclosed in a hood system
Don't Let a Stagnant System Keep Your Production from Being Flexible
- Easily transportable and quiet operation
- Powerful suction in a small footprint
- Hook up 1 - 2 fume extraction guns
- Easy to maintain, simple to operate
- Energy-efficient design allows it to work only while welding
Maximize Source Capture. Minimize Maintenance.
- Massive filter and power capacity
- Hook up 4 - 6 fume extraction guns or robotic kits with high suction
- Plumb in ductwork or utilize a hose management system
- Less maintenance, more safe welding
- Semi-portable with forklift or power jack
Super Simple and Effective Weld Fume Control.
- Wheel all around the shop to help fume capture
- Ideal for bench work or TIG welding applications
- Easy to position
- Simple to operate
- Cost efficient to use and maintain
Welding Fume is Very Dangerous to Industrial Workers
Weld fume consists of metal, process gas, and non-process gas to form a toxic air that rises, spreads, and is easily inhaled.
A study from IARC, the International Agency for Research on Cancer, classified weld fume as a Class I carcinogen in 2017, meaning welding fume is a known cause of cancer.
Local and national governments are increasingly enforcing more stringent air quality requirements to protect industrial workers.
A cleaner and safer environment not only protects industrial companies from liability, but it helps your workforce be more productive and attracts quality people to your company.
The Closer to the Arc Weld Fume is Captured, the Less it Spreads
Many of the more well-known fume extraction solutions are positioned far away from the source of the weld fume.
These measures do a good job of funneling out dirty and hazardous weld smoke, but are not able to protect the welder directly.
However, these solutions fit too far between the worker and the weld fume to protect them from breathing in these dangerous fumes.
As engineered solutions catch weld fumes closer to where it begins, the ability to limit it's spread increases.
This is why our solutions focus heavily in the most concentrated areas, where they can make the greatest impact, often at a lower cost.
Weld Fume is Best to Address at the Welding Arc
Fume extraction welding guns are not new technology. But the way they work today is.
Modern engineering has allowed us to know more about the type of static pressure needed to effectively capture weld fume depending on your parameters and your welding process.
The more restriction and the higher the parameter = the more suction power you need.
This means you need to have an adequate amount of pressure to capture those concentrated weld fumes without affecting shielding gas and without compromising the welder. Enter ABICOR BINZEL xFUME extractoion.
Which Fume Shroud is Best?
Product Overview: xFume™ Fume Extraction MIG Torch
There’s usually a question of whether all that additional design and engineering that goes into these fume guns affect the performance of the gun itself.
Is there a loss of amperage? Will it fatigue my welder more? We answer those concerns below.
While it is argued that fume guns don’t ‘perform’ as well, the answer is no, you won’t sacrifice any performance. Today’s fume extraction welding guns perform just as well as regular welding guns with capacities from 200 to 500 amp air and water-cooled for almost every possible situation a standard MIG gun handles. The guns also feature the same range of features as in a standard MIG gun.
Fume guns have been really sensitive to creating porosity from the vacuum sucking up the shielding gas and replacing the gas with oxygen. This in the past has caused a lot of bad welds and a lot of reworking which undercuts the investment into fume extraction guns and extractor systems.
You want to make sure all the vacuum you apply is not reaching the zone where the shielding gas should be. If you measure turbulence near the end of the shielding nozzle, then your flow is too strong or your shroud too close to the welding operation.
Yes, some systems do offer adjustable or dual-flow set-up. Check with whichever company you consult with on fume extraction solutions to see if they offer it.
Fume extraction units for ABICOR BINZEL's fume extraction systems do have an adjustable flow feature.
This is a great question because there are fume extraction guns that can be heavy and bulky to handle, which can affect welders’ stamina. But, even the strain of using a fume extraction torch would depend on the gun you’re changing from and the smoke gun you’re picking, because there are fume guns out there that achieve the same feel and handle as most MIG guns on the market.
It’s also a matter of welding positions. Overhead and vertical welds by their very nature are more straining weld positions than horizontal or down welds, so heavier fume extraction guns could be more strenuous and adversely affect performance because if the welding gun isn’t positioned properly it won’t capture the fume as much as it could.
However, these concerns and the guns’ performance again depends on the MIG gun being switched from and the fume gun in question. Take a demo and see if the difference is real.
You can find plenty of MIG guns out there with the swivel at the base of the cable, and there are plenty of cables out there that weigh the same as many non-fume extracting MIG torches on the market. Do your research and talk to your welding supplier or a qualified rep.
This was a common issue with the first generation of fume extraction guns. In order to fit all the additional components into the first fume extraction guns, there was a significant amount of added weight that made the gun bulky, heavy, and cumbersome to handle.
Today, with a much-increased focus on weight reduction, welder access, and torch ergonomics, modern fume guns are far more comfortable and welder-friendly tools. So much so, that some fume guns, including our own xFUME™ / RAB torch line, are actually less in weight than comparably rated, non-fume extraction MIG guns. Weld.com has a great YouTube video that covers the fume extraction weight question.
The only additional consumable a fume extraction gun requires is the fume shroud.
Other than that, you’re using the same setup as a regular MIG welding gun: diffuser, tip holder, contact tip, and nozzle.
Consumables such as the diffuser, tip holder, and contact tip are the exact same for regular BINZEL MIG welding gun as our fume extraction torches (nozzle may vary depending on fume extraction gun model). And for most other manufacturers it is also the same.
In short, no. Fume extraction guns handle any wire – whether flux-cored, metal-cored, or solid wire. However, depending on the wire used there can be more smoke produced, which is a consideration and an item to evaluate as you look at all the options with fume extraction solutions. With metal-cored and solid core, you will be looking at higher parameters normally as well as hotter gas mixes, which will translate to faster traveling smoke and more difficult welding positions to do fume extraction with for a source capture solution.
Metal-core presents one of the common misconceptions of fume extraction welding. For some, it is believed that welding metal core wire with a clean gas mix (i.e., CO2) creates a ‘clean’ smoke that doesn’t need fume extraction. This is a common myth. Toxic particles will still be released into the atmosphere from the base metal and from the wire as it melts to join into the weld joint, and without proper fume extraction equipment and procedures in place, your welders and the rest of your workers will breathe it in and be adversely affected by it.
Flux-core wire produces a very thick and visible smoke when being welded with. It also releases a lot of particulates into the atmosphere that you would want to catch at the source so as it wasn’t breathed in by your workers. Flux-core also is generally used for low parameter welding, which makes it very easy to extract at the source because lower parameter means slower smoke travel.
Get started and talk with an ABICOR BINZEL Fume Solutions expert.
Frederick, MD 21703Google Maps001-301-846-4196