Concerned girl friend,
Get your boyfriend out of there and into a safe job, somehow, anyhow. I know about guys being stubborn but for his safety and your well-being, you somehow have to get him to safety. Threaten to leave him, hide his car keys, whatever; this is like letting an intoxicated person drive.
Bob Garner
I don't know the situation but 2 things come to mind.
Either the employer is not providing protection or your boyfriend is not using what is provided. I don't meant that in a cold hearted way - it just that some folks don't use, or don't know to use safety equipment that is available.
I think we all can understand wanting to stick it out at work and not making any waves with the boss. However if the company is not providing for ventilation, or providing Personal Protective Equipment (PPE), they are in vioation of OSHA requirements. Even failing to enforce that employees must use their PPE is a violation. Maybe they don't know of the requirements (hard to believe but it can happen).
Now as for your boyfriend - he needs to look out for himself. He could think of it this way - if the boss wants him to go down to the bottom of the cliff, is he going to jump, or will he drive down the access road? Yes the employer has responsibilities but so does he. There are many things he can do to protect himself. If he is gettting flashed in the eyes, either he is in the wrong place at the wrong time, or he might be a bit overeager to get the arc started. He should stay out of places were he will get flashed by others or make sure the safety glasses are being worn - tinted, if allowed, will help. If it is his own flashes, he needs to be more careful. If he has a self darkening hood, is he inadvertently covering the sensor so it doesn't darken when it should?
Did he report the flashes to his employer? - that is supposed to happen too.
Is your boyfriend welding with his head in the smoke plume? He might not know if he is or not, but he should take steps to avoid that. Respirators are uncomfortable but lung disease is too and lasts longer. The employer should provide respirators but I'd get my own if my employer wouldn't and I wanted to still work there. Even setting up a fan to help move the smoke away will help.
But lastly, as was already stated, your boyfriend might want to consider a job elsewhere if the employer truly is not concerned with his safety.