What mistakes to avoid in welding torch extraction?

Welding torch extraction often offers a more economical and efficient alternative to systems that extract and filter air from the entire production floor. However, there are a number of things to keep in mind when using a welding torch with integrated welding fume extraction.

The laws of physics cannot be questioned: welding fumes always work their way up. Therefore, the openings of the nozzle must always be located exactly above the welding process. That way, the welding smoke is removed as soon as it forms. The ideal angle for this type of welding torch is either 45° or 60°. This guarantees not only better extraction of welding fumes but also more ergonomic welding.

Using the wrong nozzle

The nozzle is the only wear part on a torch with welding fume extraction. Many welders hesitate to use welding torches with welding fume extraction because of just this part. After all, in some cases it can restrict the view of the welding process. But for those applications, there are extraction nozzles available with specific dimensions that make the welder's life a lot easier. Always make sure that you use a nozzle intended for welding fume extraction.

Cable assembly is too long

For optimal extraction, cable length will always play a role. The longer the cable, the lower the static pressure and the lower the extraction capacity. For a mobile welding fume extraction system, optimal static pressures range between 100 and 170 m³/h. But often a cable is selected that is too long for welding fume extraction, even when the application does not specifically call for it. Every meter too many and every kink in the cable impacts the extraction result. Although there are very many good extraction units to achieve the desired performance, it may be a good idea to opt for a synchronized system. Keep the following golden rule in mind regarding cable assemblies: as short as possible, but as long as necessary.

Cleaning the inside of the welding torch

The ideal positioning of the welding torch is just above the welding process. However, the welding torch, when extracting, will not only carry welding fumes but also the product used to pretreat pieces to prevent weld spatter. After all, that will evaporate during the welding process and be extracted. All these dirt particles can remain trapped in the extraction nozzle or even in the head of the welding torch and cable assembly. These particles form an obstacle, so to speak, in the flow of the extraction and reduce the vacuum pressure. The more contamination, the more the performance of the welding fume extraction will decrease. Regular inspection and cleaning of the extraction nozzle, the neck of the welding torch and the cable assembly are therefore in order. If the particles cannot be blown out with compressed pressure, it is best to replace the affected parts.

Maintenance of the extraction unit

Each welding fume extraction unit contains a so-called dust box that reveals how many dust particles produced during welding and extracted have entered, filtered and collected in the extraction unit. Naturally, this tray must be emptied regularly. The frequency depends on the pretreatment of the material to be welded, the material itself, the welding time and the welding parameters. If the welding torch with welding fume extraction is used frequently, it is best to choose an extraction unit that has a cleanable filter, whether automatic or not. But even cleanable filters will reach a point where they need replacement. There are welding fume extraction units that indicate when the filter needs to be cleaned or replaced or when to empty the dust box.