The paper presents a review of current state of the issue of studying the mechanism of welding aerosol (WA) formation, dispersity of welding aerosol solid component and its ability to penetrate into the human body, as an important toxicological factor. It is established that there exist two main mechanisms of WA formation -due to condensation of high-temperature evaporation products and due to formation of volatile oxides on molten metal surface. Here, the molten metal drop is the main evaporation source, but weld pool and metal spatter also participate in the evaporation process. It is known that penetrability depends, chiefly, on dimensions of particles and their agglomerates: the smaller their size, the higher the penetrability. In addition to the already known paths of WA particle penetration into the body through the respiratory tract and digestive organs, nanosized particles can penetrate directly into the brain through nerve endings in the sinuses, as well as penetrate into the blood-vascular and lymphatic systems. This results in their accumulation in the bone marrow, lymph nodes, spleen and heart. Issue of searching for the methods to lower the emissions in coated-electrode welding is still urgent, chiefly due to improvement of their coating composition, as well as the ability to control particle dispersity in WA. 25 Ref., 1 Figure. K e y w o r d s : particle, welding aerosol, solid component, toxicity, penetrability, sanitary-hygienic characteristics Coated electrodes for manual arc welding (MAW) have for a long time been the object of investigations, which were initially aimed at improvement of weldingtechnological characteristics, while the next stage was lowering their production cost. At present, electrode sanitary-hygienic characteristics and searching for ways of reducing the negative influence of welding process on workers in this sector, are one of priority directions of electrode research.As manganese is the main toxic component of welding aerosol (WA) in welding low-alloyed lowcarbon steels, it was and still is one of the main objects of research [1]. This is confirmed by the Bulletin published by IIW, which actualizes the issue of WA investigation and gives several recommendations [2]:• influence of WA and dust magnesium-containing compounds in welding and related technologies should be minimized, at least, within the respective national norms;• it is worthwhile to perform further investigations to improve the understanding of absorption of these compounds (welding products); their behaviour in the human body; dose-effect interaction and any possible neurological and neurobehavioural manifestations.On the other hand, American Conference of Governmental Industrial Hygienists (ACGIH) in 2013 revised their recommendations on manganese and proposed lowering the maximum allowable concentrations (MAC) of manganese: for WA solid component (WASC) with particle size below 2.5 µm -to 0.02 mg/m 3 , and for WASC with more than 2.5 µm particle size -to 0.1 mg/m 3 [3]. Over the next several years, the a...