CFD-based assessment of welders’ exposure to welding fumes in a real-world booth

Welding produces hazardous gases, fumes, and vapors, posing health risks to operators. Practical mitigation strategies are limited. This study applied CFD to simulate welding fumes in a full-scale booth. The model specifically aims to analyze welding fume concentrations and deposition in the breathing zone across various design settings, providing practical strategies to enhance welder protection. Key exposure indicators, including airborne suspension, particle escape fraction, and deposition within the welder’s breathing zone, were quantified under different scenarios, such as ventilation rates, local exhaust ventilation (LEV) placement, ceiling geometry, and welding duration. Results indicate that doubling the inlet air velocity reduced exposure levels by 36%. Moreover, the findings demonstrate that LEV systems play a critical role in improving protection within welding workshops. Positioning the LEV directly above the welding zone, at a short distance from the welding table, reduced exposure to below 1% of the total injected particles. Additionally, pyramidal ceiling configurations were more effective in facilitating the extraction of vertical fumes compared to flat ceilings. Longer welding durations substantially increased cumulative emissions and exposure levels. These findings highlight the importance of an integrated approach that combines optimized airflow dynamics, effective LEV placement, and suitable design configurations that effectively enhance welders’ protection.