Welding Reference Card
One page. MIG, TIG, stick and flux core settings by thickness.
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Size local exhaust hoods, welding booths, and dilution airflow for cleaner shop air
Welding
Complete Welding Settings Guide
19 pages. Four processes, stainless and aluminum, symbols and inspection.
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Welding Job Estimator
Price the job, then hand over a quote with no internal numbers.
Excel or Google Sheets. Best on a computer.
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Welding Complete Bundle
Card, 19-page guide and the estimator workbook. All six files.
Excel or Google Sheets. Best on a computer.
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Recommended Welding Ventilation & PPE
Capture fumes at the source and protect the breathing zone
Top Pick
ARCCAPTAIN Auto-Darkening Helmet
- Primary weld-zone PPE
- Fast arc sensors for MIG/TIG/stick
- Wide viewing for hood placement
- Pair with ventilation for fumes
- Essential even with exhaust
Airflow
Fluke 62 Max Infrared Thermometer
- Monitor hot work areas
- Check booth and duct hotspots
- Non-contact temperature scans
- Verify ventilation placement
- Shop troubleshooting tool
Shop
VASTOOLS 6-Piece Welding Kit
- Hammer, brush, and pliers basics
- Keep work area clean for airflow
- Supports fume capture positioning
- Everyday fabrication kit
- Pairs with hood maintenance
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Why Welding Fume Ventilation Matters
Welding and cutting generate metal fumes, gases, and particulates that accumulate in the breathing zone without adequate ventilation. MIG and flux-core processes typically produce more fume mass than TIG; plasma cutting adds significant particulate and gas loads. OSHA, ACGIH, and NIOSH exposure limits apply to manganese, hex chrome, zinc oxide, and other components depending on base metal and filler. Engineering controls — especially local exhaust — are the first line of defense before relying on respirators alone.
Local Exhaust Hood vs. General Dilution
Local exhaust captures fumes at the source with a hood positioned near the arc. Target capture velocity of 100 fpm or more at the hood face for manual welding. General dilution ventilation replaces room air but does not reliably protect the welder breathing zone — it supplements source capture rather than replacing it. For production shops, dedicated welding booths with filtered exhaust are common; hobby shops often use portable fume extractors on flexible arms.
Process-Specific CFM Baselines
This calculator uses practical shop baselines: TIG at 75 CFM per station (lower fume generation), MIG at 125 CFM, flux-core at 175 CFM, stick at 200 CFM, and plasma at 300 CFM. Actual requirements vary with wire diameter, amperage, confined spaces, and alloy. Stainless and galvanized work may need higher capture rates and filtration rated for fine particulate. Always verify with an industrial hygienist when exposure limits are approached.
Hood Placement and Duct Sizing Tips
Position the hood opening as close to the arc as practical without interfering with the weld — typically within one duct diameter. Keep flexible hose runs as short and straight as possible to maintain static pressure. Size main duct for transport velocity around 2000–4500 fpm depending on particulate loading. Clean filters and inspect airflow regularly; a clogged filter drops effective CFM and defeats the installation.