HEALTH & SAFETY


ELECTRICAL CURRENT: THE UNSEEN HAZARD OF WELDING


Electrode welding: two people welding on the same component at the same time W


hen we think about manual welding, we often picture gleaming arcs, flying sparks,


and plumes of smoke. Vivid scenes like these shape our idea of welding, which is often perceived as harsh and dangerous. But this picture falls short of reality, because visible risks such as arc radiation, hot metal spatter, or welding fume can actually be managed very effectively thanks to modern protective equipment and clear safety standards. Ideally, professional welders are equipped with helmets, gloves, and protective clothing that reliably protect them from external influences. But one often underestimated aspect is a hazard that remains unseen: electrical current. Even a brief moment of carelessness can have serious consequences: A sudden


shout prompts an instinctive turn, and an unprotected hand reaches for the stick electrode. Now, the body has become part of the circuit. In cases like this, insulating work shoes or a welding mat made of nitrile rubber interrupt the flow of electricity and provide reliable protection. Electrical current always takes the


shortest path through the body between the point of entry and the point of exit. If it runs through both hands, for example, the current not only flows through the arms and upper body, but also vital organs such as the heart—with potentially fatal consequences (drawing 1).


Caution around open circuit voltage While live parts of commercially available electrical appliances are


26 / WELDING WORLD MAGAZINE - ISSUE 04 - AUGUST 2025


protected against contact, arc welding poses an increased risk because the open circuit voltage can become dangerous contact voltage—especially if the workpiece (ground) and the electrode or non-insulated parts of the electrode holder are touched at the same time. In this case, the current travels through the human body. Depending on the operating conditions,


fixed maximum limits apply to the open circuit voltage. There is an electrical hazard to humans starting at voltages of more than 25 V AC (RMS) or 60 V DC and where there is the potential for a sufficiently high current to flow at the same time.


Even low amperages can be lethal When electrical current travels through the human body, it has a stimulating effect


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