When plasma arc welding, safety is an important consideration.

Plasma arc welding is a process in which coalescence is produced by heating with a constricted arc between an electrode and the work piece (transfer arc) or the electrode and the constricting nozzle (non-transfer arc). Shielding is obtained from the hot ionized gas issuing from the orifice which may be supplemented by an auxiliary source of shielding gas. Shielding gas may be an inert gas or a mixture of gases; pressure may or may not be used, and filler metal may or may not be supplied. Plasma welding is similar in many ways to the tungsten arc process. Therefore, the safety considerations for plasma arc welding are the same as for gas tungsten arc welding.

Adequate ventilation is required during the plasma arc welding process due to the brightness of the plasma arc, which causes air to break down into ozone.

The bright arc rays also cause fumes from the hydrochlorinated cleaning materials or decreasing agents to break down and form phosgene gas. Cleaning operations using these materials should be shielded from the arc rays of the plasma arc.

When welding with transferred arc current up to 5A, safety glasses with side shields or other types of eye protection with a No. 6 filter lens are recommended. Although face protection is not normally required for this current range, its use depends on personal preference. When welding with transferred arc currents between 5 and 15A, a full plastic face shield is recommended in addition to eye protection with a No. 6 filter lens. At current levels over 15A, a standard welder’s helmet with proper shade of filter plate for the current being used is required.

When a pilot arc is operated continuously, normal precautions should be used for protection against arc flash and heat burns. Suitable clothing must be worn to protect exposed skin from arc radiation.

Welding power should be turned off before electrodes are adjusted or replaced.

Adequate eye protection should be used when observation of a high frequency discharge is required to center the electrode.

Accessory equipment, such as wire feeders, arc voltage heads, and oscillators should be properly grounded. If not grounded, insulation breakdown might cause these units to become electrically “hot” with respect to ground.

Adequate ventilation should be used, particularly when welding metals with high copper, lead, zinc, or beryllium contents.