Safety Information

Mechanical/Physical Hazards

Cutting tools and holders may fragment in use.

Metal chips can be very hot with sharp edges and should not be removed by hand. Chips can cause burns to the skin and damage to the eyes.

To ensure a safe job environment, make sure the insert and component are correctly secured in their holder before use to prevent them coming loose during the operation. Too much overhang can result in vibration and lead to tool damage/breakage and/or components with undesired dimensions.

Always wear appropriate personal protective equipment at all times, and ensure all machine guards and safety interlocks are in place prior to and during the operation for machining safety.

DO NOT USE any tool or product that shows signs of damage. Return the product to the appropriate location for repair, replacement or recycling.

Use all appropriate safety guards or machine encapsulations to securely collect particles such as chips or cutting elements that may spin off.

For rough operations, large depths of cut or when machining large diameters - make sure that the machine has the required torque and power.

At high RPMs, the weight of the insert and clamping elements increase, which can affect the clamping arrangement. It is recommended that all high-speed manufacturing takes place only in a well-protected machine set-up. Before mounting the insert, make sure that the insert and its seat are in perfect condition and free from burrs or any particles, which may seriously affect the clamping arrangement. Always use the correct clamping force when tightening the screw. Note: A 19 gram insert weighs 350 kg at 37,500 rpm.

Friction Stir Welding (FSW) tools and the materials being welded generate extreme heat during operation. The tool and workpiece can reach temperatures between 550°C and 650°C (1022°F to 1202°F), posing a significant burn hazard. Always allow sufficient cooling time before handling the tool, workpiece, or surrounding fixtures. Use heat-resistant gloves and other thermal protection when necessary.

Avoid direct contact with the tool or workpiece during and immediately after welding, as both retain high residual heat capable of causing severe burns.

Fixtures and clamps in close proximity to the weld zone may also reach high temperatures and should be handled with care.

Thermal stress from the FSW process may cause material distortion or unexpected movement. Ensure adequate precautions are taken when working near the weld area.

FSW tools require precise calibration of axial force, rotational speed, and travel speed to ensure safe operation. Inadequate parameters may result in poor weld quality, excessive tool wear, or equipment damage.

Dust and Fume Hazards

Hard metal products and tools should not be reground or sharpened without taking appropriate safety measures to prevent exposure to dust (e.g. ventilation and personal protection equipment). Operations such as grinding, cutting, burning and welding of hard metal products may produce dust or fumes, which can be inhaled, swallowed or come in contact with the skin and eyes. Dust may cause inflammation of the airways and irritate the nose, throat, skin and eyes. Repeatedly inhaling high levels of hard metal dust has been reported to cause hard metal disease (interstitial lung fibrosis). In a two-year study on rats and mice, inhalation of cobalt was shown to cause cancer.

FSW processes involving reactive materials (e.g., aluminum or magnesium) can produce fine oxides or particulates during operation. Ensure proper ventilation or localized exhaust systems are in place to prevent inhalation risks.

Welding on painted, anodized, or coated materials may release hazardous fumes. Always evaluate the material surface treatments and ensure adequate fume extraction systems are operational.

Sensitizing Hazards

Prolonged skin contact with uncoated hard metals may cause an allergic skin reaction. Handle hard metal products and tools in a way that avoids direct skin contact, or use gloves for a safe job environment. Cobalt and hard metal are known sensitizers, having the potential to cause allergies through repeated exposure. A sensitized person could react with asthmatic symptoms or eczema.

Prior to using the product, always review and understand the Safety Data Sheet or Safety Information Sheet for that particular product.

FSW tools made from tungsten carbide or other cobalt-containing materials may cause sensitization. Handle tools with care and always wear gloves during setup and removal.

Specific Chemicals in Products

Lead is commonly used in steel and brass to improve machinability, in general in accordance with applicable ISO standards. Some of our tools and adaptors contain small articles made of such steel and/or brass. These small articles can therefore contain up to 0.35% (in steel) – 4% (in brass) w/w lead, though the concentration of lead is significantly smaller in the entire tool/adaptor. Lead is classified as carcinogenic and toxic to reproduction. However, this classification does not mean that materials or components containing lead pose an immediate hazard. Under normal operating conditions, the use of articles containing such components does not require any special safety precautions beyond normal safety procedures such as gloves. 

Disposal of all waste products and containers shall be made in accordance with local, state/provincial, federal and national regulations.

Preventive Measures

Avoid formation and inhalation of dust. Use adequate local exhaust ventilation to keep personal exposure below the nationally allowed limits.

If ventilation is not available or adequate, use nationally approved respirators.

Avoid skin contact. Wear suitable gloves. Wash skin thoroughly after handling.

Use suitable protective clothing. Launder clothing as needed.

Do not eat, drink, or smoke in the working area. Wash skin thoroughly before eating, drinking or smoking.

Use safety goggles or glasses with side shields when necessary.

Always wear appropriate safety equipment.

For machining safety, only operate equipment when all necessary guards, interlocks and other safety devices are in place and functional.

DO NOT use or operate damaged tools or products.

Ensure operators are trained in the specific safety procedures for FSW tools, including proper setup, operation, and maintenance. Emergency stop procedures must be clearly understood.