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THE USE OF THORIATED

TUNGSTEN ELECTRODES

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Introduction

Tungsten electrodes are used when arc welding with the Tungsten Inert gas (TIG)

process or when plasma welding. In both processes the electrode, arc and weld

pool are protected from atmospheric contamination by an inert gas. A tungsten

electrode is used because it can withstand very high temperatures with minimal

melting or erosion. Electrodes are made by powder metallurgy and are formed to

size after sintering.

TIG welding electrodes usually contain small quantities of other metallic oxides

which can offer the following benefits:-

facilitate arc starting

increase arc stability

improve current-carrying capacity of the rod.

reduce the risk of weld contamination

increase electrode life

Oxides used are primarily those of zirconium, thorium, lanthanum, yttrium or

cerium. Additions are usually of order 1%-4%. All these oxides greatly improve arc

initiation, especially when direct current (DC) welding is employed. Thorium oxide

(thoria) has been used for many years having been found effective in terms of long
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life and thermal efficiency. Zirconium oxide (zirconia) has been commonly used for
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alternating current (AC) TIG welding, normally for welding aluminium.
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Hazards

Thorium (Th) is slightly radioactive with a long half life and emits mainly alpha (α)

particles, but occasionally some beta (β) and gamma (γ) radiation is emitted. Alpha

particles cannot penetrate skin or even paper. However, they are harmful if

released inside the digestive tract, or inside the lungs, where they act as a

carcinogen.

Thorium oxide is, therefore, a low level radioactive material which may give rise to

both a small external radiation hazard and an internal hazard from ingestion or

inhalation. The external hazard estimated for a welder holding an electrode for a

whole year is a very small fraction of the maximum permissible radiation dose and

it is concluded that the external radiation hazard is likely to be negligible.

There is almost no release of radioactive material during arcing. However, to

achieve maximum arc stability the electrode tip is ground to a conical point before

use. This shape is maintained during use by regular regrinding. During the

grinding process, particles of tungsten may be produced with thoria on the

surface. It is these dust particles that create the major hazard, as they may be

inhaled, and the thoria may release alpha particles from the surface.

In a review of air sampling measurements carried out during grinding it was

concluded that during grinding air concentrations could approach or even exceed

concentrations at which it would be necessary to consider designating the area as

a controlled area as defined by the Ionising Radiation Regulations 1999.

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However, the risk of cancer towelders
in TIG our newsletter to receive
due to thoria exposure is very low, since

the exposure times tothe latest news

individuals are and eventssmall.
invariably from The
TWI:Danish Welding

Institute estimates that ofSubscribe > TIG welders, a cancer incidence of 0-3
1200 full-time

may occur during a thirty year working life. While this figure is considered

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acceptable, the Danish Welding Institute has recommended that thoriated

tungsten be phased out in Denmark since non-radioactive alternatives are

available.

Safe working conditions

Storage

It is recommended that thoriated electrodes are stored in steel boxes, clearly

labelled with the radiation trefoil. When stored in closed boxes, there is no

significant hazard in handling and storage.

Small numbers (1 day's supply) of electrodes can be handled by welders safely

without any special precautions.

Preparation/Grinding

Grinding creates the greatest hazard as the exposed tungsten/thoria area is

greatly increased and fine particles of potentially radioactive dust are released into

the atmosphere.

It is recommended that a dedicated grindstone with local dust extraction is used,

and a simple filter mask is worn unless the number of electrodes used is very

small (less than about 20 per year). If the grinding wheel is not fitted with a

protective viewing screen, eye protection should be worn. The air extract from the

grindstone should be arranged so that the particles are deposited into a

substantial disposable bag.

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A safe method of collecting and handling the dust from the collection unit must be
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used to minimise release to the atmosphere (for example, it could be placed in a
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sealed paper/plastic bag.)

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The area round the grinding wheels should be cleaned daily with a vacuum cleaner

to remove dust particles. If a high efficiency vacuum cleaner is not available, then

the material should be damped down to minimise dust.

Workers should be encouraged to wash their hands before using the toilet

facilities, and before taking work breaks, and for this reason the washing facilities

should be close to the work areas.

Welding

Some vaporisation of tungsten does occur during welding but it is a very small

amount and the corresponding level of radioactivity is extremely low. No special

precautions are necessary.

However, as with grinding thoriated tungsten electrodes, wearing mouth, nose and

eye protection during welding would further reduce any risk of contamination.

Alternatives to thoriated tungsten

Lanthanum, cerium, yttrium and zirconium oxides can all be used with tungsten.

While they are all marginally radioactive, the risk is even lower than with thoria, so

no specific precautions are needed. The general consensus of users is that

ceriated or lanthanated tungstens are acceptable alternatives to thoriated

tungstens, particularly with a DC current, while zirconiated tungsten is preferred

for AC current welding. There are very minor differences in the arc voltages

required for equal currents between the various alternatives. Consideration

should be given to justifying the use of thoriated tungsten electrodes in preference

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to other suitable alternatives.
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Official guidelines

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The International Institute of Welding Health and Safety Commission VIII states

that there are no specific hazards regarding storage, handling or welding but dust

extraction equipment should be used on the grindstone and respiratory

protection should be worn by the operator during grinding. This is covered by the

Health and Safety Executive Guidance note HS(6) 53 The selection, use and

maintenance of respiratory protective equipment.

In the UK the use of thoriated tungsten electrodes is subject to the Ionising

Radiations Regulations 1999. Exposure must be kept as low as is reasonably

practicable, and the guidelines in the previous sections are designed to achieve

this.

Local rules and adequate supervision are required. The employer must appoint a

Radiation Protection Supervisor (RPS), who should be responsible for

1. The implementation and monitoring of all health and safety procedures

for the storage, grinding, use and disposal of thoriated tungsten
electrodes and all by-products.

2. Keeping records of the amount of thoriated tungsten in store, and the

numbers of electrodes issued to each welder.

3. Giving instruction in the correct use and grinding procedures to the

welders. These procedures should be in the form of written instructions,
in addition to verbal presentations. The welders must know the name to
the RPS.

4. Monitoring to check that the welders are carrying out the grinding
procedures Subscribe
correctly, and that
to our the dust extraction
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effectively.
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Recommended reading

Ionising Radiations Regulations, 1999. L121 Approved Code of Practice and

Guidance.

The Control of Substances Hazardous to Health (COSHH) Regulations 2002 -

L5 Approved Code of Practice and Guidance.

HSE Guidance note HS(G) 53 Respiratory protective equipment at work.

HSE Information Document: Storage and Use of Thoriated Tungsten 564/6.

Arc Welder at Work, Welding Manufacturers Association leaflet No. 236

BS EN ISO 6848:2004 Arc welding and cutting. Non consumable tungsten

electrodes.

BS EN 1011-4: Welding - Recommendations for Welding of Metallic Materials.

Part 4: Arc Welding of Aluminium and Aluminium Alloys.

ANSI/AWS A5.12/AS.12M 98 (R2007) Specification for Tungsten and Tungsten

Alloy Electrodes for Arc Welding and Cutting

IIS/IIW-VIII 1582-91 Estimated Radiation Doses From Thorium and Daughters

Contained in Thoriated Welding Electrodes

IIS/IIW VIII 1702-93 Health Aspects in the Use of Thoriated Tungsten

Electrodes.

Occupational Hygiene Vol. 1 No.1, 1994, 'Cancer Risk and Thoriated Welding
Electrodes' Subscribe to our newsletter to receive

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