Welding Flashback vs Burnback: What's the Difference?

Does your job involve welding? According to the U.S. Bureau of Labor Statistics (BLS), roughly a half-million workers sustain a welding-related injury in any given year. Some of these injuries are minor, whereas others are more serious. While welding-related injuries can be attributed to many different factors, two of the most influential factors consist of flashbacks and burnbacks. By understanding the difference between flashback and burnback, you can protect yourself from injury when welding.

What Is Flashback?

Flashback is a welding phenomenon in which the flame travels into the torch's supply tank. Welding, of course, involves the use of a torch that's connected to a supply tank. The end of the torch will produce a flame, which is fueled by the supply tank. You can apply this flame to workpieces or materials to weld them together. With flashback, the flame may essentially travel in reverse by going into the supply tank.

What Is Burnback?

Burnback, on the other hand, is a welding phenomenon in which the wire "burns back" into the torch's tip. Most welding torches have a wire. As electricity flows through the wire, it creates a spark that's responsible for the flame. With burnburn, the wire may fuse together with the tip. It's a relatively common problem that many workers experience when welding.

Differences Between Flashback and Burnback

Flashback and burnback are two completely different things. Flashback occurs when the flame of a welding torch travels into the torch's supply tank. In comparison, burnback occurs when the wire of a welding torch burns into the torch's tip. If your job requires you to use a welding torch, you should strive to eliminate instances of flashback and burnback. 

Flashback is far more dangerous than burnback. When flashback occurs, it may lead to an explosion. Some instances of flashback only involve the flame entering the supply tank's hose. In other words, the flame won't reach the actual supply tank. Nonetheless, hoses contain fuel. If the flame enters the hose, it will ignite while triggering a small explosion. Other instances of flashback can lead to a larger and more serious explosion, though. If the flame works its way all the way into the tank, a large explosion may occur.

In addition to understanding the differences between flashback and burnback, you should wear the right personal protective equipment (PPE) when welding. Welding requires certain types of PPE. You'll need a welding mask, for instance, as well as welding gloves. Depending on where you work, you may want to invest in a welding curtain as well.