What Size of Fume Extractor Do I Need for My Welding Projects?

Welding fume extraction is crucial for maintaining a safe and healthy work environment. Welding fumes contain harmful substances that can pose serious health risks, including respiratory issues and long-term illnesses. For more detailed information on these health risks, refer to Are Welding Fumes Toxic?

Welding fume extractors are essential tools designed to capture and remove these hazardous fumes at the source, ensuring cleaner air and a safer workspace. To understand more about what welding fume extractors are and how they work, visit What is a Welding Fume Extractor?

What Extractors Should You Use

Choosing the right extractor depends on your welding process. Here’s a quick guide:

Process	MIG Gun	Arm	Nozzle	Hood	Table
MIG / GMAW	Best	Yes	Yes	No	No
TIG / GTAW	No	Best	Yes	No	No
Fluxed-Cored / FCAW	Best	Yes	Yes	No	No
Stick / SMAW	No	Best	Yes	No	No
Robotic Welding	Yes	No	No	Best	No
Aluminum Welding	Best	Yes	Yes	No	No
Cutting / Grinding	No	No	No	No	Yes

• MIG and Flux-Cored: The fume extraction MIG gun is the best option, but flexible arms and extraction nozzles are also effective.
• TIG and Stick: The best choice is an arm, complemented by a nozzle.
• Robotic Welding: Use fume extraction hoods for the best protection.
• Aluminum Welding: A MIG gun is ideal, with arms and nozzles as alternatives for TIG and other processes.
• Cutting / Grinding: Downdraft tables are the recommended choice.

Select the extractor that best matches your welding process to ensure efficient fume extraction and a safer working environment.

Size of the Extraction Tool

Fume Extraction MIG Gun

The size of the fume extraction MIG gun you need mostly depends on your welding parameters, particularly the maximum power or amps, duty cycle, and shielding gas. When choosing a brand, you can pick from your favorites such as Airgomig, Binzel, or Bernard. It is crucial to check the specifications of each model to determine which one suits your needs best. For more info: Fume Extraction MIG Guns

Flexible Arm

When selecting a flexible arm, the general rule is that smaller is better because it is cheaper to buy and operate, and takes up less space. To determine the appropriate size, ideally, you should measure the longest weld you frequently make and divide it by five. Based on this measurement, you can choose between a 3, 4, or 6-inch diameter arm. For more info: Fume Extraction Arms

Nozzle

For nozzles, the principle remains that smaller is better for cost-efficiency and space-saving. In most cases, a 2-inch nozzle is recommended as it is often used with portable units designed for them. However, in some rare instances, you might need a 3 or 4-inch nozzle if you can supply the necessary airflow. For more info: Fume Extraction Nozzles

Hood

Hoods are primarily used for welding robots and do not provide adequate protection for welders. When using a hood, ensure it covers the entire operational area of the robot. For more info: Fume Extraction Hoods

Downdraft Table

Downdraft tables are specifically used for cutting or grinding and are not efficient for welding (since welding fumes naturally rise). The size of the downdraft table you need depends on the size of the parts you are working on. For more info: Downdraft Tables

Size of the Vacuum Unit

Choosing the right vacuum unit is crucial to ensuring efficient fume extraction. The vacuum unit must provide the required airflow during operation, taking into account pressure drops, which differ from maximum airflow. For detailed information, you can check out our webinar.

To determine the appropriate operating airflow for different tools, consider the following:

• MIG (extraction over 2.5 inches): 100 cfm
• MIG (extraction less than 2.5 inches): 70 cfm
• 3″ arm: 200 cfm
• 4″ arm: 300 cfm
• 6″ arm: 600 cfm
• 2″ nozzle: 200 cfm
• 3″ nozzle: 300 cfm
• 4″ nozzle: 400 cfm
• Hood: depends on size
• Downdraft Table: depends on size

When using automatic valves, you can opt for a smaller unit by considering the duty cycle and diversity factor, which refers to the maximum number of welders welding simultaneously. For setups with fewer than five welders, portable units are usually sufficient. However, for more extensive operations, a central system is recommended. To explore the pros and cons of mobile versus stationary fume extraction units, you can visit this link.

Size of the Dust Collector

When selecting a dust collector, aim for an air-to-cloth ratio of 1:1. This means if you have 1000 cfm in operation, you will need a dust collector with at least 1000 square feet of filtration surface. Ensuring you have a filter with a MERV-13 rating or higher is crucial for effective filtration. Higher MERV ratings indicate better filtration efficiency, which is essential for capturing fine particles and maintaining clean air. For more information on choosing the right filter for welding fume extraction, visit MERV Ratings: Choosing the Right Filter for Welding Fume Extraction.

Conclusion

Proper fume extraction is essential for maintaining a safe and healthy welding environment. By carefully selecting the appropriate size of your extraction tools, vacuum units, and dust collectors, you can ensure efficient and effective fume control tailored to your specific welding projects.