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Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

https://doi.org/10.1007/s10967-019-06967-y

Aerodynamic diameter distribution of aerosols from plasma arc


cutting for steels at different cutting power levels
Min‑Ho Lee1 · Wonseok Yang1 · Nakkyu Chae1 · Sungyeol Choi1

Received: 2 October 2019 / Published online: 2 December 2019


© Akadémiai Kiadó, Budapest, Hungary 2019

Abstract
Radiological aerosol generated from radio-activated metal cutting is a significant risk factor that must be considered for
radiological hazards on a worker. For minimizing the exposure of a worker, it is important to understand the distribution of
particle size and mass. This study measured the aerodynamic distribution of aerosols generated from the plasma arc cut-
ting on steel alloys by using an electric low pressure impactor. We compared the impact of plasma cutting conditions with
various plasma arc current (75, 90, 125 A) and cutting length (3, 6, 15 cm) on the aerodynamic distribution of aerosols. We
confirmed the higher plasma arc current, the more aerosol with a larger particle than 0.1 μm was produced. The optimal
current value of suppressing ultrafine dust generation was suggested through the analysis of kerf width and fine particle
fraction by increasing plasma arc current. The study of plasma arc current influence on aerosol generation could be helped
to potentially minimize worker’s exposure by carefully selecting the cutting conditions.

Keywords  Plasma cutting fume · Plasma arc current · Kerf width · Aerodynamic distribution · Fine particle

Introduction material up to 40 mm thickness of tube, pipe, and reactor


vessel [7–9].
A plasma arc is commonly used for metal fabrication and However, the plasma arc cutting generates a large num-
cutting process. Plasma cutting is a method of cutting metal ber of fine and ultra-fine particles compared to other non-
by generating hot plasma arc so that it can be applied to con- thermal cutting processes [6]. Despite safeguards regula-
ductive materials such as aluminum, mild steel, and stainless tions and respiratory protection equipment on workplace,
steel [1, 2]. Despite the limitation that plasma cutting cannot the aerosol from plasma cutting is still a serious problem
be used in non-conductive materials, plasma cutting is more that threatens the health of the worker. Radiological aerosol
utilized, less energy consumption, and more mobile to carry that occurs during the process of radio-activated metal cut-
out work at various locations on the site than other cutting ting can be an important risk factor that must be considered
processes such as oxy-fuel, laser, and water jet [3]. There- for radiological hazards as well as for the harmful effects
fore, many plasma cutting applications have been performed of metal toxicity [10–12]. However, while aerosol studies
on thick mild steel or stainless-steel plates [2]. Because of on existing welds are abundant [13–20], only few limited
these advantages, plasma arc cutting has been selected as studies on looking into the properties of plasma arc cutting
one of the ways to cut large quantities of metal which gener- fume and health risks from exposure has been conducted [5,
ated from dismantling process of nuclear power plants [4–6]. 21]. It is important to understand the correlation between
There were some cases of using plasma arc as a tool for cut- the operating parameters of plasma cutting and the charac-
ting radio-activated metal components in decommissioning teristics of fume, instead of simply applying the knowledge
nuclear facilities projects. A plasma arc was used for cutting learned from the welding fume.
The characteristics of aerosol generated by plasma cutting
are theoretically determined by the type of metal and the
* Sungyeol Choi
sungyeolchoi@kaist.ac.kr operating parameters such as cutting speed, cutting length,
and plasma arc current. Bernard et al. [22] and Novick et al.
1
Department of Nuclear and Quantum Engineering, Korea [23] analyzed the effect of plasma power on amount of
Advanced Institute of Science and Technology, 291 aerosol in the metal cutting process. However, the previous
Daehak‑ro, Yuseong‑gu, Daejeon 34141, Republic of Korea

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614 Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

researches were not enough to judge the effect of the operat- to control the cutting speed and cutting length automatically.
ing parameters of plasma cutting on characteristics of aero- The movement of metal plate was controlled at 100 μm per
sol. In this study, we focused on the relationship between step by servo motor in the Y-direction (Fig. 1).
plasma arc current and formation of aerosol in the perspec-
tive of safety for workers. The aerodynamic diameter distri- Metal plate sample and cutting condition
butions of aerosol particles produced from plasma cutting
on different steel materials such as 304 alloy, 316 alloy, and The sample metals were processed with a thickness of
mild steel were measured at various power levels, 75, 90, 10 mm for placing on the dross box. Three different samples
125 A, and cutting lengths, 3, 6, 15 cm. The real-time sam- (SS304, SS316L, mild steel) with different chemical com-
pling and in-situ characterization of aerosols were achieved positions were selected for plasma cutting. A SS304 steel
from 6 nm to 10 μm at 14 stages. In this study, we tried to is composed of 17.5–19.5% Cr, 8–12% Ni, 2% Mn, 0.1%
identify not only the generated total amount of aerosols, but N, 0.75% Si, 0.045% P, 0.03% S, 0.03% C, with the rest of
also the number and mass distribution of aerosols generated Fe. A SS316L stainless steel is composed of 16–18% Cr,
from the plasma arc cutting according to the variation of cut- 10–14% Ni, 2–3% Mo, 2% Mn, 0.1% N, 0.75% Si, 0.045%
ting length and arc current. By comparing both total amount P, 0.03% S, 0.03% C, with the rest of Fe. The main differ-
and aerodynamic distribution of aerosol, it showed that the ence between SS316L and SS304 steel is the molybdenum
plasma arc current could induce significantly shifted the content. SS316L steel is austenite chromium–nickel stainless
aerodynamic distribution. Because the small size of aerosol steel containing 2–3% molybdenum, which increases corro-
can be more critical to the health of worker, the aerodynamic sion resistance and strength at high temperatures. Mild steel
distribution and fine particle fraction of aerosol should be is composed of most Fe with 0.6–0.9% Mn, 0.2% C, 0.05%
concerned for the safety of worker. Therefore, the control of S, 0.04% P. Mild steel, also called plain carbon steel, is cur-
arc current could be useful to minimize the potential haz- rently the most common form of steel because it provides
ard of aerosol for the worker. This experimental data on the acceptable material properties for many applications while
characteristics of the plasma cutting fume will be useful in the price is relatively low. Unlike other stainless steel, it has
the evaluation of potential health risks associated with both a high carbon content and low levels of chromium or nickel.
metal fabrication and nuclear industry in the cutting process. Low-carbon steel contains about 0.05–0.25% carbon, which
is flexible and ductile.
The cutting speed was fixed at 10 mm/s. The minimum
Experimental value of plasma arc torch current was set to 75  A, the
minimum ampere for cutting metal samples at a speed of
Fume chamber and automatic metal cutting system 10 mm/s. The plasma arc cutter was set at various plasma
current levels of 75, 90, and 125 A, and cutting lengths of 3,
In laboratory experiments, an isolated fume chamber was 6, 15 cm. Before the metal cutting process, the blower was
designed to measure aerosol particles produced without operated for at least 10 min to make a cleanroom environ-
external leakage. The chamber was designed to be 1.3 m ment. Metal oxide particles and gases produced during the
wide, 1.0 m long, and 0.66 m high. Clean air was continu- cutting operation were extracted from the fume chamber to
ously drawn into the chamber through a HEPA filter installed the sampling pipe. The generated fume was measured for
on the side of the chamber. Fume produced by metal cutting 4 min after the end of the cut, the time when the aerosol
was released through a sampling pipe with the opposite side concentration was reduced to the background level. All three
of the chamber installed the air inlet port. The sampling metals were found to be cut to the completely opposite side
line was installed as short as possible without bending for in all operating conditions. The kerf width increased as the
minimizing measurement error. Also, the inner walls of the plasma arc current used for metal cutting increased (Fig. 2).
chamber and the sampling pipe were coated to prevent parti- The kerf widths were measured by using the digital caliper
cle losses by sticking to the surface. A blower pump operated (CD-15APX, Mitutoyo Co.), which has a rated accuracy of
at a flow rate of 1700 L/min. 0.02 mm and a resolution of 0.01 mm. In the case of mild
A plasma cutter (Powermax 125, Hypertherm) was used steel, the cutting lengths in frontside were shown very simi-
to cut the steel plate. The plasma cutter was fixed in the lar to those in the backside. On the other hand, SS304 and
center of the chamber ceiling. The plasma cutting device SS316L could not be completely cut the backside of the
operated up to 125 A current with supplying compressed metal in the 75 A and 90 A current cutting environment.
air. An automatic cutting system was designed for reproduc-
ibility of experiments consists of a dross box, a servo motor,
a programmable logic controller, and a touch screen. The
movable table controlled by the servo-motor system helped

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Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624 615

Fig. 1  The metal chamber for


aerosol measurement from
metal cutting in KAIST Nuclear
Fuel Cycle Lab. The plasma
cutting device (Powermax 125,
Hypertherm) was fixed in the
center of the chamber ceiling.
A metal sample was moved into
setting position by the servo-
motor system at a constant
speed

Particle size and mass distribution measurement different 14 size stages. All of measured distribution data
were converted into the normalized form to compare each
Metal fume is released externally through sampling pipes, distribution form directly. Because of the broad range of
some of which are used for analysis through an isometric the measurement from 6 nm up to 10 μm size, linear scales
sampler. Particle measurement was performed by using an make it hard to distinguish the peaks in the distribution
electric low pressure impactor ­(ELPI+®, DEKATI). Since data. Instead, the size distribution function is usually plot-
the generated amount of metal fume exceeds the E ­ LPI+ ted as a lognormal form describing in the following equa-
measurement limit, a diluter (eDiluter™, DEKATI) with tions [24–28]. Normalized number per logarithmic diameter
fixed 1:60 dilution factor was connected before E ­ LPI+ input denoted by a “(dN/N)/dlogDp” (Eq. 1) and normalized mass
port (Fig. 3). per logarithmic diameter denoted by a “(dM/M)/dlogDp”
The ­ELPI+ consists of a unipolar corona charger, a cas- (Eq. 2) were plotted along the Y-axis.
cade impactor, and sensitive electrometers. Because the par-
dN dN
ticles are charged by unipolar corona chargers, they transmit = (1)
N × d log Dp N × (log Dp,u − log Dp,l )
electrical signals to the 14 collection stages. The measured
current signals are converted to the number and mass con- where N is the total number of particles, dN is the number
centration using particle size dependent relations describ- of particles in the range.
ing the properties of the charger and the impactor stages.
The medium point of cut-off aerodynamic diameter in col- dM dM
= (2)
lection stages were 0.006, 0.0146, 0.0289, 0.0541, 0.0946, M × d log Dp M × (log Dp,u − log Dp,l )
0.155, 0.256, 0.381, 0.602, 0.947, 1.63, 2.47, 3.65, 5.36, and
9.88 μm when the sampling rate is 10 L/min. All particles where M is the total mass of particles, dM is the mass of
of size from 6 nm to 10 μm are collected in each of the particles in the range, and dlogDp is the difference in the log

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616 Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

Results

Number and mass aerodynamic diameter


distribution of different metal plate

We compared the number and mass aerodynamic diam-


eter distribution under different operation conditions on
SS304, SS316L, and mild steel. The distribution data were
converted into the normalized form to compare each dis-
tribution form directly. The normalized distribution form
is used to avoid confusing from the different total counted
value.
For SS304 cut, mass aerodynamic diameter distribution
showed a bi-modal distribution which has two peaks at
0.256–0.602 μm and 3.65–9.88 μm (Fig. 4), whereas, num-
ber aerodynamic diameter distribution showed a single-
peaked distribution at 0.0946–0.381 μm (Fig. 5).
For SS316L cut, both mass and number aerodynamic
diameter distribution showed a similar trend for SS304
(Figs.  4, 5). The mass aerodynamic diameter distribu-
tion of SS316L showed a bi-modal distribution which has
two peaks at 0.256–0.947 μm and 5.36–9.88 μm (Fig. 6),
whereas, number distribution of SS316L showed a single-
peaked distribution at 0.155–0.602 μm (Fig. 7).
However, the number distribution of mild steel showed
a different trend to those of SS304 and SS316L (Figs. 5,
Fig. 2  Kerf width and cutting length obtained in plasma arc cutting 7). The mass distribution of mild steel showed a bi-
on a SS304, b SS316L, and c mild steel modal distribution with two peaks with 0.256–0.602 μm
and 3.65–9.88  μm was the same as in the preced-
ing case (Fig.  8). For the number distribution of mild
of the aerodynamic diameter width. dlogDp is calculated by steel, however, the addition of a peak was shown at
subtracting the log of the lower stage aerodynamic diameter 0.006–0.0146 μm, showing bi-modal distribution the same
­ LPI+
(logDp,l) from the log of the upper stage (logDp,u) in E as the form of mass distribution (Fig. 9).
properties.

Fig. 3  Schematic of the isoki-


netic sample extraction system
for particle measurement using
eDiluter™ and ­ELPI+®

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Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624 617

Fig. 4  Mass aerodynamic diameter distribution of 304 stainless steel cle symbol with dash line represented at 6 cm of cutting length. The
cut with plasma cutter operated at a 75 A plasma arc current, b 90 triangle symbol with dash-dot line represented at 15  cm of cutting
A plasma arc current, and c 125 A plasma arc current. The square length
symbol with solid line represented at 3 cm of cutting length. The cir-

Fig. 5  Number aerodynamic diameter distribution of 304 stainless steel cut with plasma cutter operated at a 75 A plasma arc current, b 90 A
plasma arc current, and c 125 A plasma arc current

Effect of plasma power on the aerodynamic with a mass value of 156 to 593 mg/m3. It was found that
distribution of aerosols under the same experimental conditions, the mass was
increased by 4.5 times in SS316L steel cutting and 2.5 times
As the plasma arc current increased from 75 to 90 A and in mild steel cutting.
125 A, the total mass of particles generated from metal cut- However, the relationship between the total parti-
ting was increased (Fig. 10). In the 15 cm cutting condi- cle number and arc current showed different tendencies
tion which is most evident in increasing effect, SS304 cut depending on the type of metal material and cutting length
confirmed that the total mass increased by about four times (Fig. 11). In the plasma cutting on SS304 steel with 15 cm
when the plasma current was increased from 75 to 125 A, cutting length, the total number of particles under 125

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618 Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

Fig. 6  Mass aerodynamic diameter distribution of 316L stainless steel cut with plasma cutter operated at a 75  A plasma arc current, b 90  A
plasma arc current, and c 125 A plasma arc current

Fig. 7  Number aerodynamic diameter distribution of 316L stainless steel cut with plasma cutter operated at a 75 A plasma arc current, b 90 A
plasma arc current, and c 125 A plasma arc current

A condition was 40,242,511 cm −3 indicating a 2.6-fold to 22,869,071 cm−3 at 125 A condition. In addition, the
increase from the number of particles 15,381,365 cm −3 particle number change tendency varied depending on
under 75 A conditions. It was a slight increase com- the cutting length. As can be seen in Fig. 11c, a different
pared to the total mass increase of 3.8 times. In contrast, relationship between the total number of particles and arc
the total number of particles in mild steel cut tended to current was observed when the cutting length conditions
decrease by 0.68 times from 33,448,539 cm −3 at 75 A were 3 cm, 6 cm and 15 cm on mild steel.

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Fig. 8  Mass aerodynamic diameter distribution of mild steel cut with plasma cutter operated at a 75 A plasma arc current, b 90 A plasma arc
current, and c 125 A plasma arc current

Fig. 9  Number aerodynamic diameter distribution of mild steel cut with plasma cutter operated at a 75 A plasma arc current, b 90 A plasma arc
current, and c 125 A plasma arc current

Discussion distributed has a bi-modal form which has an additional peak


at the lowest stage.
Effect of steel type on the mass and number During the plasma arc cutting process, aerosol parti-
aerodynamic distribution cles are generated by complex mechanisms. Molten metals
are vaporized and formed the volatile oxides or explosion
Mass aerodynamic diameter distribution showed a bi-modal of metallic droplets or a burst of gas bubbles. Plasma arc
distribution, whereas the number aerodynamic diameter dis- welding has been studying very widely [13–20, 29–40]. In
tribution showed a single-peaked distribution on SS304 and contrast, plasma arc cutting studied by few researchers [4,
SS316L steel. In mild steel cutting, however, the number 21–23]. Plasma arc cutting and plasma arc welding are simi-
lar processes; however, the origin of the aerosols is different
[2]. The previous researches [6, 21] confirmed that the vapor

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620 Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

Fig. 10  Total particle mass produced as a function of the plasma arc current on a SS304, b SS316L, and c mild steel. The cutting length was set
at 3 cm, 6 cm, and 15 cm

Fig. 11  Total particle mass produced as a function of the plasma arc current on a SS304, b SS316L, and c mild steel. The cutting length was set
at 3 cm, 6 cm, and 15 cm

pressure of chemical element has a proportional relation The reason for the difference in number and mass distri-
with the fine particle fraction of the aerosol. Although the bution is that the mass of a single particle collected at the
primary contents in the steels are iron, the different compo- upper stage, which means particle size larger than 1 μm, is
nent ratios of chemical elements in metal could affect the significantly greater than that of a smaller particle. Although
aerodynamic diameter distribution. Comparing the chemi- it is showed that there are few particles with a size of 1 μm
cal composition of the three metals, only mild steel has the or more in the number distribution, they have a significant
characteristics of high carbon content and low levels of chro- effect on the mass distribution. The bimodal aerodynamic
mium or nickel. Therefore, the difference in number distribu- diameter distribution indicates that the dominant mechanism
tion can be induced because the component ratio of chemical of aerosols generation from plasma arc cutting process is
elements in mild steel is different from other metals. the vaporization process [21, 41, 42]. While the evaporation
process causes a peak at 0.1 μm, once the aerosol seeds are

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created, they form particles larger than 1 μm through the has increased by up to 4.5 times and at least 1.5 times. It is
growth process [6]. a similar result that higher arc current induces more fume
generation in the previous study. Wang et al. [2] also con-
Effect of plasma current on the amount of aerosol firmed that the high current created a greater number of fine
generation and fine particle fraction particle and oxidation level. The effect of plasma current on
the number aerodynamics distribution is related to the physi-
It was confirmed that plasma arc current is an important fac- cal and chemical properties of cutting materials. The steel
tor affecting the kerf size and the amount of plasma fume. consists of each chemical element having a different boiling
The kerf width indicates the amount of material loss during point. Therefore, increased the temperature of the spot area
the cutting process. Therefore, minimizing the kerf width at high plasma current may induce the liquid droplet explo-
is a major factor in reducing additional work by increasing sion of an element having a lower boiling point. The liquid
cutting quality. The previous studies showed that kerf width droplet explosion can cause larger sizes of aerosols to gener-
was sensitive to the changes in the plasma cutting param- ate. Therefore, the high plasma current can generate more
eters such as cutting speed, plasma gas pressure, and arc amount of large size aerosols than the low current, because
current [43–45]. Adalarasan et al. [44] showed that a higher of the increasing the possibility of liquid droplet explosion.
value of arc current resulted in increasing kerf width. This The health effects of ambient particular matter (PM) has
study also found that both kerf widths in the frontside and been studied a lot about lung cells [46–51]. Depending on
backside increased as the plasma arc current increased on the aerodynamic diameters, PMs are generally classified
steel alloys (Fig. 12a, b). Consequently, the low plasma arc into three categories: ­P M 10, ­P M 2.5, and ­P M 0.1. ­P M 10 is
current might be seen as beneficial for cutting. However, inhalable coarse particles, which are coarse particles with
the selection of low plasma arc current has a challenge on a diameter between 2.5 and 10 μm. P ­ M 2.5, well known
the thick metal cut. In Fig. 12c, the cut length in backside for fine dust, refers to fine particles with a diameter of
at 75 A and 90 A plasma arc current did not seem to be suf- less than 2.5 μm. P ­ M0.1 refers to ultra-fine particles with
ficient to cut the SS304 and SS316L metal plate. If the metal a diameter of less than 0.1 μm. P ­ M2.5 and ­PM0.1 can eas-
cutting is not completed, it will be necessary to repeat the ily enter the pulmonary alveoli where gas exchange takes
cutting process resulting in additional aerosol exposure to place and cross the membrane of lung cells [51]. There-
the worker. That means the plasma arc cutting at a high cur- fore, inhalation of P­ M2.5 and P­ M0.1 can damage not only
rent could have the advantage to reduce the risk of rework. breathing but also other organs because these particles
However, it was confirmed that the high current condition can spread to the blood circulation system through lung
increased the total mass of the aerosol generated. cells [47, 49]. In this study, a quantitative analysis was
As shown in Fig. 10, the total mass of particles resulting attempted by calculating fine particle fraction to confirm
from the increase of plasma arc current from 75 to 125 A

Fig. 12  Variations of kerf width in a frontside and b backside of the metal according to the increase of plasma arc current. c Comparison of the
cut length in backside of the metal with plasma arc current

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622 Journal of Radioanalytical and Nuclear Chemistry (2020) 323:613–624

Fig. 13  Number fraction of fine particle generated during the 3 cm cut of a SS304, b SS316L, and c mild steel. The total number of ultrafine
particle ­(PM0.1) was defined by the number fraction of aerosol below the 0.1 μm size

the effect of plasma arc current on PM generation. The fine There was a limitation in this study that did not take
particle fraction (FPF) was calculated by following Eq. 3: into account important variables such as material thickness
and cutting speed. Nevertheless, the analysis of the effect
dNx2 − dNx1
FPFx1−x2 = (3) of plasma arc current on the distribution of aerosols and
N fine particle fraction could be a significant point in that the
where ­F PF x1–x2 is fine particle fraction between lower optimal plasma current was suggested for minimizing the
sized x1 μm and upper sized x2 μm; N is the total number of worker’s aerosol inhalation risk.
particles collected, and dNx is the number of particles less
than x μm sized.
The FPF was classified into three groups according to Conclusions
the aerosol size: ­FPF0.006–0.01, FPF0.01–0.1, and ­FPF0.1–2.5.
The ­F PF 0.01–0.1 has shown a tendency to continue to The characteristics of plasma cutting fume are significantly
decrease with the increase of plasma arc current. At the associated with the plasma cutting parameters such as type
same time, the ­FPF0.1–2.5 tended to increase as opposed of metal, cutting length, and plasma arc current. We con-
to ­FPF0.01–0.1 result (Fig. 13). In conclusion, because the firmed the plasma arc current that could affect the number
fraction of aerosol particles larger than 0.1 μm increases, and mass aerodynamic diameter distributions of aerosols
a high plasma arc current could lead to an increase in total in plasma arc cutting on the various steel such as SS304,
aerosol mass generated from metal cutting. Because most SS316L, and mild steel. The total aerosol mass resulting
aerosols were smaller than 2.5 μm, there was little differ- from the increase of plasma arc current from 75 to 125 A
ence in the total number of P ­ M2.5 generation. However, was increased by a minimum of 1.5 to a maximum of 4.5
the total number of ­P M0.1 generation reached the mini- times depending on cutting conditions, while the number of
mum a low point in 90 A arc current on SS304 and mild total particles increased up to 2.6 times and in mild steel cuts
steel. For the cutting on SS316L, the total number of ­PM0.1 tended to decrease inversely. Through the calculation of fine
was a slight decrease until 125 A arc current condition. particle fraction, we concluded that increasing plasma power
Therefore, it was possible to determine the optimization contributes greatly to increasing the overall particle mass
of the plasma arc current from a safety perspective that by promoting the particle growth process. Furthermore, the
minimizes the risk of ultrafine particle inhalation. Fur- optimal plasma current was suggested for minimizing the
ther research will be needed because the effects of aerosol worker’s aerosol inhalation risk. This experimental study
generation and kerf width on the increase of plasma arc could be helped to potentially minimize worker’s internal
current could be different depending on the type, thickness exposure by carefully selecting the plasma arc current.
and cutting speed of the cutting material.
Acknowledgements  This work was financially supported by the
National Research Foundation of Korea (NRF) by a grant funded

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