Helmet Head

Proper welding attire in action. PHOTO COURTESY OF MILLER ELECTRIC.

The helmet is the most important piece of safety equipment for a welder. It shields the eyes from intense light and the face from the radiation emitted by the spark. And it will dissipate some of the fumes that are emitted when welding.

“A good helmet protects the eyes and skin not only from severe sparks but also from potentially vision-damaging ultraviolet and infrared rays emitted by the arc,” says Jamy Bulan, commercial equipment product manager for Lincoln Electric. “The right helmet must be able to be worn easily and comfortably for a full day’s work, providing flexible adjustments, while protecting a welder’s eyes and face from spatter and sparks and harmful light rays.”

Not only is the helmet a source of safety, “a welding helmet also gives wearers an opportunity to add a bit of personal flair to their welding gear,” he adds. “With this in mind, welding helmets today are available in a wide range of colours and graphics. These visual features obviously command attention, but a helmet’s protective features, combined with comfort considerations are what welders should consider when selecting the right helmet for their needs.”

Welding helmets have evolved a great deal and are continuing to evolve. “Some recent innovations include arc tracking, which allows the helmet lens to track arc-on time during the welding process,” explains Eric Sommers, product manager, weld safety - head and face protection for Miller Electric.

“This data can be used to calculate productivity to help determine if additional operator training is necessary to improve efficiencies.

“Another innovation is electromagnetic arc sensing on auto-darkening helmets. With this technology, the sensor picks up the magnetic frequency of the arc to eliminate any interference, meaning that the lens will darken only when the arc initiates and it will stay dark while the operator is welding. This technology works outdoors, too, where the sunlight could possibly interfere.”

While auto-darkening helmets comprise the biggest chunk of the market and have the most new innovations in them, traditional fixed shade helmets still have their uses. “Traditional shield (passive) helmets are still used in large numbers, as these helmets are a low-cost option to an automatic, high-definition helmet,” says Guy Shelverton, global product manager, personal protective equipment, with ESAB.

“Traditional helmets usually have advantages over automatic styles in terms of cost, weight and maintenance/servicing requirements. For welders who carry out single application work, where there’s no need to change the shade level at which they operate. The traditional shield helmet is usually a suitable option.” The trend, however, is moving towards auto-darkening helmets as they are becoming less expensive and offer other benefits that traditional helmets do not.

Viking 700G autodarkening helmet, Iron Man 2

“Companies commonly see cost savings through improved operator efficiency and productivity, while users appreciate that auto-darkening helmets help reduce fatigue on their neck by eliminating the need to nod down their helmet,” says Sommers. This last point is salient for anybody who has struggled to learn welding using a traditional helmet. “Welding helmets featuring a fixed shade can be more difficult to use because a welder has to lift the helmet every time he or she wants to examine the weldment and joint, set position and prepare for welding and then flip the helmet down again when it’s time to strike the arc,” said Bulan. “This repetitive movement can case neck strain and fatigue after a full day’s work. Also, for less-experienced welders, it can be difficult to keep the MIG gun, TIG torch or stick electrode in the correct position to begin welding in the joint after the helmet is lowered into place. Poor weld starts can result in weld defects, something any welder obviously wants to avoid.”

When choosing a helmet there are really only two criteria that should be met—safety and comfort. “While everyone’s perception of comfort is different, there are many options for headgear and helmet weights that allow individuals to tailor a helmet exactly to his or her liking. Additionally, the cushioning in helmets today has improved and the presence of more adjustable settings help welding operators find the right fit,” said Sommers.

“Today’s helmets are considerably more functional than those of even 10 or 15 years ago,” said Bulan. “All, including the most inexpensive, must meet strict safety standards across the globe. In the United States, that standard is ANSI Z87.1 and in Canada it is CAN/CSA Z94.3. These standards address such concerns as light leakage and flame and impact resistance.”

Whereas helmets of the bygone era were one size fits all, today’s welder has a myriad of options to choose from. If you are performing many different welding processes, jumping from Stick, to TIG to MIG, then an auto-darkening helmet with shade control, which can switch from 6 to 13 in some instances, is necessary.

“Some processes, like TIG welding on thinner materials, call for lower shade levels to adequately see the weld puddle to control the arc and judge appropriate travel speed,” he says. “Welding on thick materials at high amperages generally requires higher shade levels.

“The helmet’s viewing size also is a major factor to consider. While it is based on preference, the amount of out-of-position welding performed can affect the amount of viewing area needed in a helmet. Some of the largest view sizes in auto-darkening models measure 3.82 x 2.44 inches or larger, which aids in delivering a clear natural view in combination with the helmet’s LCD technology.”

Some models allow the user to control delay and sensitivity that will adjust when the auto-dark will kick in. “For example, if there are other welders operating very close by, the helmet’s arc sensor sensitivity can be reduced to help prevent triggering or darkening when those nearby welders strike their own arc,” he says. “Delay controls can be used to lengthen or shorten the amount of time it takes for the helmet to return to the light state following the completion of a weld. This can be helpful when tack welding, when the weld duration is short and the operator plans to move quickly. On the other hand, performing lengthy welds on thick materials may require that the delay be set for longer periods of time so that the operator does not have to view the larger, hotter weld nugget at the end of the weld until it has cooled for a second or two. Generally delay can be set for 0.5 seconds up to two seconds.”

Basic and less expensive auto-darkening helmets will have one or two arc sensors, while premium models generally have four arc sensors. “With more arc sensors, there is less chance that the helmet will fail to darken as necessary,” said Bulan.

Some auto-darkening helmets have grind mode which lets the welder keep the helmet on while grinding the weld—it will provide protection from the sparks and light of the grind. Helmets can have their controls on the outside or inside the helmet, and this is a personal preference where the outside controls are convenient while the internal controls are more protected from the harsh welding environment.

An externally mounted variable shade adjustment knob on a helmet from Lincoln Electric. PHOTO: NESTOR GULA

If working in an environment that requires hard hats it is worth noting that not all helmets are hard-hat compatible.

Options for helmets range from respirators that will pump in air for work in extremely toxic environments to lenses that aid the welder to see the weldment better.

Unlike the helmets of yore, the new helmets, while still robust, are more sensitive than the old ones. “There are some basics that can help make a helmet last a long time,” says Sommers. “These include reducing the number of impacts a helmet sees from drops, and storing the helmet within the manufacturer recommended temperature ranges. Also, before welding, allow the helmet to warm to room temp if it has been stored in a cold area.”

The auto-darkening filter is powered by solar lenses, lithium batteries or both. These should be inspected and made sure they work before embarking on a welding task.

“More than 90 per cent of the cost of an automatic helmet is related to the auto-darkening filter (ADF) lens. ADFs are subject to the same hazards as all electronic devices, so it’s important to follow basic precautionary guidelines: take care not to drop or bang/knock the helmet, ensure water does not get into the electronics, and keep the helmet from overheating,” says Shelverton.

“It’s also critical that, as common maintenance, wear parts be changed regularly. The most common wear and spare parts of the helmet are the front cover lenses and inside cover lenses. Based on the type of work, these lenses can be changed as much as twice a day or once a month. To ensure the best quality of view to the welder, the welder should consider changing and/or cleaning these lenses regularly.”