A primer on autodarkening weld helmets

It’s important for a welder to play with the functions of the helmet and look at the recommendations and limits. ANSI Z49.1 is a good starting point for recommended shades for the welding process and amperage. ArcOne

Welding can be dangerous if not done properly. Shops and welders can do many things to ensure that they go home safely each day and limit exposure to hazards. One of the most important pieces of safety equipment in a welder’s arsenal is a welding helmet, which protects the welder from radiation, sparks, spatter, and many other hazards that he or she may encounter. But with so many options available on the market, it can be hard to know what helmet makes the most sense.

Helmet Style

Two common welding helmets available today are passive and autodarkening.

The most standard type is a passive welding helmet that offers a tinted lens often in shade 10. This option tends to be very economical and suited for welders who are working in constant conditions, performing the same type of welding on one type and thickness of material. It is often a more lightweight option but does not offer the flexibility of an autodarkening helmet.

“A passive helmet has some advantages,” said Todd Scheerer, welding application technologist, Fronius Canada Ltd., Mississauga, Ont. “It is almost always glass, whereas the autodarkening tends to be plastic, which makes it that much clearer. Glass offers a better optical refraction when it comes to welding, and from my experience and many others’, it tends to be very clear.”

It is important to note that this style of helmet does not switch from a light state to the darkened state. The darkened lens remains constant in the down position. This can be problematic for welders as they may need to remove the helmet to properly inspect the weld and during setup in between welds.

“A welder using a passive helmet will have to flip the lens up and down throughout the day,” said Jim Watkins, senior product manager, ArcOne, a Walter Surface Technologies Brand, Montreal. “This can lead to repetitive stress on welders’ bodies, and particularly their neck. Also, during setup times and as welders begin the process, if they touch the torch to the metal while the lens is up, they will get flashed. There is a higher potential for error, and welders need to actively engage their eye protection.”

One way to limit these challenges is to wear a fixed-shade autodarkening helmet. For welders who want some added protection but don’t require a range of lens shades, this might be a good option. It also tends to be more economical than more advanced technologies.

For welders that work with a number of different welding processes and materials, a variable-shade autodarkening welding helmet makes sense. This style of helmet’s shade can be adjusted based on the welding process, material, and application.

“An advantage of an autodarkening helmet, whether fixed or variable, is that it makes working in tight spaces much easier,” said Scheerer. “A welder has the ability to have the helmet down when getting ready to weld, so they don’t need to constantly reposition themselves to remove or flip the helmet. It really makes things much easier and allows for welding to begin without any manoeuvring. It can also be used with a grind mode, so the welder doesn’t need to switch over to a grind shield.”

Variable-shade Autodarkening Helmet Features

These helmets offer a range of features and specifications that make it easier for welders to perform safely and comfortably.

Some welding helmets can communicate with a power source via Bluetooth, allowing it to darken prior to ignition rather than waiting until the arc is lit. Fronius

Light State. When a welder is not welding, the helmet filter should be light enough for clear visibility of the workspace. Most helmets have a light state of shade 3 or 4. This can be adjusted based on the environment, such as working outdoors in different weather conditions.

Sensitivity. Most variable-shade autodarkening helmets allow the welder to adjust how sensitive the helmet is to light. This feature offers greater usability and comfort for welders, especially if they work in a variety of environments with ranging welding conditions and applications. Two welders working with the exact same parameters may require different sensitivities for their individual visibility needs.

“Most fixed-shade products have fixed sensitivity,” said Watkins. “The sensors are not able to be adjusted for user sensitivity. However, with variable-shade helmets, we often see variable sensitivity, which is quite important.”

Viewing Area. Helmets offer a range in terms of the viewing area. The experts agree that viewing size has gotten larger over the years. However, the smaller viewing area provides a more focused view that can be preferable to some welders, especially if he or she is working on very small components or features. Helmets with larger viewing areas tend to be heavier than those with smaller ones, so if that added weight presents an ergonomic challenge, then the welder has options.

“Depending on the application, a larger viewing area can improve a welder’s productivity,” said Watkins. “It may also be more comfortable than having the welder move and adjust his positioning to see.”

Display Features. Most helmets are available with true colour, and many higher-end options come with advanced display technology for enhanced clarity, quality, and colour. This is especially important in the light state, where colour differentiation and details are needed.

“In the past, most filters tended to have a green or red tint to them,” said Watkins. “This made it very hard to see true colours of the weld or surrounding environment. Having HD technology and true colour is a benefit to the welder, making it easier to view actual conditions, which in turn makes it safer.”

Connectivity. The newest helmets have integrated smart technology to enhance autodarkening features.

“Some helmets can communicate with the power source through Bluetooth, which allows it to darken the helmet before the arc starts,” said Scheerer. “This helps ensure there is no long-term eye strain or issues. It’s a great safety feature for career welders.”

Shade Applications

Generally, variable-shade autodarkening helmets have shades from 9 to 13, although some offer shades 4 through 8, primarily for grinding and cutting operations. When the helmet is in the down position, the welder will be able to see through the light state that allows for clear visibility of the weld for inspection and surrounding area for setup. Once the weld arc is struck, the helmet will automatically darken. It’s important for welders to ensure the correct shade is used for their welding application.

Which lens shade is needed depends on a few factors: welding process, amperage, and material type.

“Starting at the lightest, shade 2 or 3 is good for a grinding process,” said Scheerer. “Moving up to stick welding and short-circuit welding, shade 9 or 10 is recommended. When you get into metal core and spray welding, you want to use a darker shade, like a 12 or 13.”

Within these processes are amperage ranges, so the shade may need to be adjusted. Similarly, using the same process and amperage on a different material can change the arc intensity, meaning that the material type will also play a role in how dark a shade needs to be.

“Unlike steel, aluminum is far more reflective,” said Watkins. “So, you tend to want to increase the shades for comfort because it's a brighter weld. It’s important to note, though, that our filters always have full ultraviolet and infrared protection regardless of shade. It’s static protection.”

Tips and Tricks

When welders first start working with a variable-shade autodarkening helmet, it’s important for them to know that the recommendations are just that. Many charts are available with information on the minimum protection levels and shade recommendations based on years of expertise. However, every welder is different.

“It’s important for a welder to play with the functions of the helmet,” said Watkins. “Look at the recommendations and limits. ANSI Z49.1 is a good starting point for recommended shades for the welding process, amperage, and whatnot. We would recommend always starting with a darker shade and moving lighter to get the best view rather than the other way around. But it’s important for the welder to be comfortable with the shade, as long as it’s within the proper limits. Some welders need a darker shade, some need a lighter. So play around and find what works best.”

Beyond initial use, maintaining and keeping the helmet in good working order is important, especially as it relates to the autodarkening function.

“The biggest thing I would recommend is make sure your helmet viewing area is clean,” said Scheerer. “Damage to the eyes can be caused by improper cleaning of the lens, like using paper towels and rubbing instead of microfleece and gently dabbing and rinsing. This can cause damage to the coatings on the lenses, which block UV light. Dirt and residue can also damage this coating over time, which in turn lets in damaging rays. That’s what can cause serious and permanent eye damage.”

Associate Editor Lindsay Luminoso can be reached at lluminoso@canadianfabweld.com.

ArcOne, www.arc1weldsafe.com

Fronius, www.fronius.com