There’s more to selecting a welding helmet than choosing one by what your buddy uses or because of the cool graphics on it. The decision can impact your safety and the quality of your work. This article identifies what is important, from the basics to the “nice to have” features that will help to distinguish the best helmet for your needs.
All these options beg the question: What kind of welder are you? Are you just getting started as a welder in a trade school or have you been welding for most of your career? After all, there are different types of helmet shoppers – from those looking for the highest quality, best comfort, best clarity and biggest viewing area to those looking for a basic helmet at the best value to everything in between.
Darkening ability
A basic passive welding helmet only provides one shade (shade 10), limiting the types of work a user can do. They must constantly move their head up and down, taking their eyes off the welding point, which can create inaccuracies.
An auto-darkening helmet – which is also known as a variable helmet – features an electronic cartridge lens that changes from a light stage to a dark stage in milliseconds. A variable helmet provides shades of 5 to 13, giving the user the opportunity to use it for a variety of applications, including grinding and cutting as well as TIG, MIG and stick welding.
With an auto-darkening, variable-shade helmet, users can choose the shade based on the work application. For an example, for stick welding, they might choose a darker shade 11 where more eye protection is needed, but for TIG welding, they might choose a lower amperage shade 5.
When grinding or cutting, a lower amperage shade is needed. For the majority of auto-darkening helmets, the shade cannot be adjusted during a process, but the shade can be changed to reflect different needs for different projects without switching helmets.
Because shade adjustments are made in milliseconds, an auto-darkening helmet is safer, eliminating the potential of flashbacks from outside of the work area that might occur with a basic helmet. Auto-darkening technology also eliminates the need to move or adjust the helmet when striking an arc, making it easy to see the weld plate.
An auto-darkening helmet replaces the need for several helmets when working on different welding processes. One auto-darkening helmet covers a variety of applications.
High-def lenses
Many auto-darkening helmets are available with a high-definition cartridge lens, which is a newer technology that enhances the viewing area so the user can see the workpiece, the weld and the numbers on the machine clearer than a standard glass lens. Standard glass lenses have been used for many years in the welding industry, and some welders like them because they are familiar and comfortable with them.
Some old timers are not confident that the cartridge lens is safe, even though it is safer compared to the old-style lens. Sometimes, veteran welders aren’t comfortable with new technology. They might have the perception that a shade 10 glass lens cannot fail because there are no electronics in it. But there are so many filters in the auto-darkening cartridge itself that even if the cartridge were to fail, it still blocks harmful UV light, and the user is still protected.
Clarity ratings explained
Every cartridge lens is tested using four different methods determined by American National Standards Institute (ANSI) to establish its optical clarity. This rating is designated on every auto-darkening lens and packaging. Each lens is rated on the four tests and has four numbers indicating its rating. In each category, the lens is rated “good” (3), “better” (2) or “best” (1).
- Accuracy of vision. The first number represents the lens distortion. A 1 means that distortion is eliminated and there is accuracy of vision through the lens.
- Diffusion of light. The second number represents uniformity. Is the lens uniform throughout the entire viewing area? Is the shade the same in all areas of the lens? A 1 indicates complete uniformity with the diffusion of light through the lens.
- Consistent shade. The third number represents consistent shade in all areas of the lens. No matter where a beam of light hits the lens, the shade will be consistent.
- Angle dependence. The last number indicates the degree to which the shade remains consistent when the user’s head moves and the angle of the work changes.
Ideally, users should seek a rating of 1:1:1:1, which represents optimal clarity indicating that the lens has a perfect view, free of defects and distortion.
Helmet tech and consumables
Auto-darkening helmets have arc sensors that are programmed to sense when a welder is striking an arc and automatically provides the shade that has been programmed. The number of arc sensors on a helmet can vary; typically, there are at least two or three, and the better helmets will have four arc sensors. Additional arc sensors provide an aspect of safety. If, for example, one of the sensors is blocked by a piece of metal and can’t receive the light from the arc, one of the alternate sensors can. The more sensors, the better the helmet picks up the arc.
Solar-powered helmets energize from the surrounding light and when there is not enough power, a battery backup takes over to keep the helmet in operation.
Welding helmets are dependent on consumable items, such as the outside cover lens, which protects the auto-darkening lens from spatter and dirt. Most users want to buy helmets that have consumables that are easy to obtain.
The outside cover lens must be replaced quite often, especially with a lot of stick or MIG welding. When welding, little fragments of metal fly off and hit the front of the hood and stick to the protective lens, so the auto-darkening lens isn’t damaged. An industry-standard outside cover lens measures 4.5 in by 5.25 in. and can be found at any professional supply store or hardware store.
The cover lens needs to be replaced depending on how many metal pellets hit the lens and how dirty it gets. Once the cover lens gets cloudy or full of spatter, it can affect safety and work quality and runs the risk of damaging the helmet.
For the battery, the industry standard for welding helmets is CR 2450, which can be readily found in any supply house or even local retail stores. Some helmets can require difficult-to-find and expensive batteries that could put the user out of commission until the battery is located. This is also the case with an odd-sized cover lens.
Sensitivity and delay features
Some welding helmet lenses have a sensitivity and a delay feature that is helpful. If there is a lot of light around, the user may want to turn sensitivity down, or when it’s dark, turn the sensitivity up. The light from the arc will read correctly and go to the shade the user requests. If there are other welders around, their arcs can interfere by changing the lens shade. By adjusting the sensitivity, other arc welding will not affect the auto-darkening lens.
Welders can increase or decrease the delay via a delay switch, which offers levels from one to five. If a welder is putting down a bead, when they lift the electrode holder off the metal plate, the lens will go from the shade that they have set to a lighter shade. Also, there are times they might want to delay the shade depending on the application. Not all helmets have features like a delay switch or sensitivity switch; these are signs of a better helmet.
Another popular and often requested option that some better helmets provide is grind mode, offering the opportunity to set the lens to lighter to be able to better see the grinding work when the eyes don’t need protection from welding. For safety, a blinking light reminds the user that they are in grind mode, so that they don’t start welding before switching back.
Head gear and materials
Users generally shop for welding helmets based on comfort. As viewing areas are getting bigger, helmets are getting heavier. If a user is welding all day, it’s important to have ergonomic head gear that will remain comfortable and well-balanced on the head without putting pressure on the temples. Higher end helmets have three-point adjustable head gear with an L-shaped bracket that centers the helmet as opposed to basic one-strap head gear that runs down the middle of the helmet.
Users should seek the more advanced, ergonomic head gear that feels comfortable and lightweight. Head gear should also have a ratchet so it can be securely tightened to the head.
Typically, helmet shells are constructed of thermal plastic material that can vary in thickness. Thinner construction, while it might feel lighter and more comfortable, can warp when exposed to hot temperatures.
For welders doing overhead or pipeline welding, the material of the shell is more critical, and fiberglass material is recommended. For safety reasons, users may be required to attach a welding helmet to a hard hat. This can be accomplished with adapters.
Basic or premium?
Users can purchase an auto-darkening helmet priced on the lower end without a lot of features or a top-of-the-line one priced at a premium, which includes all the bells and whistles and optimal clarity. Everything in between is available based on features and quality.
There are many different features on a welding helmet that can help welders to safely and efficiently carry out their work. Part of the choice can include helmets with interesting and edgy graphics in a range of colors. This consideration of a helmet is strictly personal preference. Many users choose plain black so they can customize it with decals and other graphics for their own unique, individualized style.
Welders should examine what they will use the helmet for and be aware of what will be most beneficial to their situation. They should ensure they are getting the features they need and the best-quality lens they can afford.
