Which of the following welding processes is most associated with generating significant smoke and fume?

The process most associated with generating significant smoke and fume is Flux-Cored Arc Welding (FCAW). This welding technique utilizes a tubular wire filled with flux, which, when heated during the welding process, generates a substantial amount of smoke and fumes as it vaporizes.

The flux in FCAW serves several purposes, including providing shielding to the weld pool and contributing to the chemical composition of the weld. As the flux is consumed during the welding operation, it releases gases and particulates, leading to higher fume production compared to processes that do not use flux or do so minimally.

In contrast, Gas Metal Arc Welding (MIG) produces fewer fumes since it generally uses solid wire without the additional flux materials that generate fume. Tungsten Inert Gas (TIG) welding is also known for producing much less smoke and fume, primarily because it uses a non-consumable tungsten electrode and produces a cleaner arc with fewer contaminating substances. Submerged Arc Welding (SAW) is typically conducted under a blanket of granular flux, which helps to minimize fume generation rather than contribute to it.

Thus, FCAW's inherent characteristics around the use of flux and the conditions under which it operates make it the process with the most