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Materials
Volume 18
Issue 24
10.3390/ma18245534
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Morphology of Fumes from Hybrid Laser–Arc Welding of X5CrNi18-10 Stainless Steel

by
Janusz Adamiec
1,
Joanna Wyciślik-Sośnierz
2,*,
Jolanta Matusiak
2,
Michał Urbańczyk
2,
Marcin Lemanowicz
3,
Robert Kusiorowski
4 and
Anna Gerle
4
1
Faculty of Materials Engineering and Digitalisation of Industry, Silesian University of Technology, 40-019 Katowice, Poland
2
Łukasiewicz Research Network—Upper Silesian Institute of Technology, 44-100 Gliwice, Poland
3
Faculty of Chemistry, Silesian University of Technology, 44-100 Gliwice, Poland
4
Łukasiewicz Research Network—Institute of Ceramics and Building Materials, 31-983 Cracow, Poland
*
Author to whom correspondence should be addressed.
Materials 2025, 18(24), 5534; https://doi.org/10.3390/ma18245534
Submission received: 2 October 2025 / Revised: 14 November 2025 / Accepted: 25 November 2025 / Published: 9 December 2025
(This article belongs to the Special Issue Fusion Bonding/Welding of Metal and Non-Metallic Materials)
Versions Notes

Abstract

Stainless steels are widely used across many industrial sectors, including the fabrication of welded structures. The most common methods for joining these materials are arc welding processes. Increasing demands for higher weld quality and process efficiency have led to a growing adoption of laser-based technologies in industry. One of the most frequently applied techniques is hybrid laser–arc welding (HLAW), which combines two heat sources—the laser beam and the electric arc—acting simultaneously. For new, innovative joining technologies, a critical factor in their implementation is their impact on the environment and human health. This article presents the results of a study on the morphology of fumes emitted during the HLAW of X5CrNi18-10 (1.4301) stainless steel. Laser diffraction and scanning electron microscopy were used to characterize the fume morphology. The International Agency for Research on Cancer has classified welding fumes as a carcinogenic agent to humans. The results revealed that more than 20% of particles generated during hybrid welding belong to the most hazardous fraction, as they can penetrate beyond the laryngeal region. These particles exhibit a homogeneous elemental distribution, with the chromium content standing at approximately 20% and nickel nearly 10%.
Keywords: welding fume; morphology; stainless steel; hybrid welding; laser diffraction; SEM-EDS (Scanning Electron Microscopy with Energy Dispersive Spectroscopy) welding fume; morphology; stainless steel; hybrid welding; laser diffraction; SEM-EDS (Scanning Electron Microscopy with Energy Dispersive Spectroscopy)

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MDPI and ACS Style

Adamiec, J.; Wyciślik-Sośnierz, J.; Matusiak, J.; Urbańczyk, M.; Lemanowicz, M.; Kusiorowski, R.; Gerle, A. Morphology of Fumes from Hybrid Laser–Arc Welding of X5CrNi18-10 Stainless Steel. Materials 2025, 18, 5534. https://doi.org/10.3390/ma18245534

AMA Style

Adamiec J, Wyciślik-Sośnierz J, Matusiak J, Urbańczyk M, Lemanowicz M, Kusiorowski R, Gerle A. Morphology of Fumes from Hybrid Laser–Arc Welding of X5CrNi18-10 Stainless Steel. Materials. 2025; 18(24):5534. https://doi.org/10.3390/ma18245534

Chicago/Turabian Style

Adamiec, Janusz, Joanna Wyciślik-Sośnierz, Jolanta Matusiak, Michał Urbańczyk, Marcin Lemanowicz, Robert Kusiorowski, and Anna Gerle. 2025. "Morphology of Fumes from Hybrid Laser–Arc Welding of X5CrNi18-10 Stainless Steel" Materials 18, no. 24: 5534. https://doi.org/10.3390/ma18245534

APA Style

Adamiec, J., Wyciślik-Sośnierz, J., Matusiak, J., Urbańczyk, M., Lemanowicz, M., Kusiorowski, R., & Gerle, A. (2025). Morphology of Fumes from Hybrid Laser–Arc Welding of X5CrNi18-10 Stainless Steel. Materials, 18(24), 5534. https://doi.org/10.3390/ma18245534

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