Next Generation Welding Helmets Offer Benefits for Operator ...

New helmet technologies

Helmets play a critical role in a successful welding operation, impacting welding operator safety, operator comfort, weld quality and overall productivity. 

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There are many reasons why companies should stay updated on new helmet technologies and invest in them for the benefit of their employees. Advanced helmet technologies help companies and their workforce meet safety regulations and compliance requirements, including those set by the Occupational Safety and Health Administration (OSHA). Focusing on compliance helps companies avoid potential fines that could impact the bottom line. It also helps prevent the rising cost of workplace injuries and related downtime, which can be addressed, in part, by taking steps to keep employees safe and protected with proper PPE, including the best possible welding helmet. 

Having the right helmet can also have a positive impact on welding operator output, since a more comfortable welding operator is typically more productive. 

Why is the proper welding helmet so important?

Today’s welding helmet technologies continue to evolve and give companies and welders a lot to consider when shopping for a helmet. That said, safety and physical well-being lead the way. 

Eye injuries are among the most common injuries in welding environments, and there is an increased push in the industry to prevent them. Musculoskeletal injuries in the neck and back muscles can also become an issue long term, especially if a welding operator wears a poorly designed helmet or if he or she has poor welding posture.

A properly designed welding helmet offers greater protection against such issues. A helmet that has a good viewing area and a lens with auto-darkening helmet technology reduces eye strain when looking at the weld joint. It also minimizes the need for “nodding” associated with putting traditional welding helmets in place by using a forward-neck motion.

What to look for in a welding helmet

It’s important to choose a helmet that provides the welding operator the necessary protection against the identified hazards in the workplace, while also allowing him or her to comfortably weld without restraint. Welding helmet manufacturers continue to respond to this need. The latest helmets on the market offer numerous distinct advantages, including:

• Reduced helmet weight and improved balance to help minimize torque on the welding operator’s neck and lessen fatigue.
• A larger viewing area and better peripheral vision that give the welder a clearer view of the weld pool, weld joint and overall work area without causing discomfort.
• Improved clarity thanks to advancements in lens technology, which can provide a brighter light state, twice the clarity and enhanced contrast of the workpiece for a better view of the welding arc. The combination of these features, like on the new ClearLight 2.0 welding helmet, gives welders more confidence while they work, allowing them to see the weld pool more clearly and therefore avoid costly mistakes and lessen rework.
• Headgear is an important factor in the comfort of a welding helmet. The Legacy headgear has a flexible, ergonomic design and incorporates a comfort cushion at the back of the head to help achieve maximum comfort for all-day wear. 

Additional factors to consider:

• Next-generation welding helmets are designed with the thinnest and lightest materials available that don’t compromise durability. Slim designs featured in newer helmets also allow entry into tight spaces for welding, making it safer and easier to get the job done.
• Some next-generation welding helmets are specifically designed to be used in conjunction with low-profile half-mask respirators, providing a comfortable solution that protects the welding operator from weld fumes.
• Shell color can also impact comfort and cooling. Lighter colors, like silver, are best for high heat applications since they don’t absorb as much heat.

Respiratory and non-respiratory helmet options

Increased awareness of weld fume issues continues to support the value of implementing the proper respiratory protection — such as powered air purifying respirators (PAPRs) — in conjunction with a properly designed helmet. Helmet assemblies come in various options to best meet application needs. Supplied air respirators (SAR) are another option that provide clean, breathable air and relief from heat stress through cool air.
 
With the increasing stringency of the industry’s weld fume regulations, along with a more vested interest by companies in safety, companies may find the need for varying levels of respiratory protection (e.g., half-mask, PAPR or SAR systems).

Few manufacturers provide the modularity and variety in their helmet offering to encompass all those solutions. Look for products that provide the ability to easily select and switch between respiratory solutions that are most comfortable for welding operators and best fit their needs.
 
Recent technology advancements are designed to drive productivity, safety and comfort in respiratory helmet options. These include airflow improvements — specifically, designs that offer airflow distribution over the front of the welding operator’s face and side of his or her head. By targeting airflow at these areas where blood vessels are located, the cooling effect is maximized as the airflow works to enhance the human body’s natural thermoregulation process. The ability to customize where the air blows on their face helps keep welding operators more comfortable and productive.
 
Welding operator comfort and productivity can also be impacted via the improved head seal designs available in today’s respiratory helmets. In these helmets, the head seal is the fabric that drapes around the welding operator’s neck to keep weld fumes out. Newer helmet designs enhance comfort by using softer material for sensitive areas surrounding the neck and face.
 
Lastly, newer generations of respiratory helmets are designed to distribute weight so the respiratory components act as a counterbalance to the front-heavy welding lens, which minimizes strain on the welding operator’s neck.

Welding helmet headgear 

A proper helmet is more than just the hood. Headgear is what secures the helmet to the user’s head, making it a critical component of helmet safety.

When selecting headgear, it is important to consider helmet usage throughout the day (i.e., intermittent or continuous). If a welder is frequently flipping the hood up and down, certain headgear styles are more durable for that repetitive motion, including the Miller® Legacy headgear. For a welder using respiratory helmets or who is involved in applications where they stay hooded and/or hood-down most of the day, other styles like the Miller® Gen IV — which is created with more flexible materials — provide a secure fit that’s comfortable for all-day wear.

Because not all people have the same preferences, it’s important to look for a helmet that allows for the headgear to be interchangeable. This gives welders the option to pair their favorite helmet with a headgear system that best suits their head size and shape (or their length or lack of hair). This mix-and-match approach helps create a comfortable fit, and in turn improves the helmet’s stability, enhances safety and makes compliance more likely. Plus, a better fit requires fewer adjustments, which means more productivity on the job.

Just as helmet technology has evolved to improve visibility, weld pool clarity and overall weight to suit a host of welder applications and preferences, headgear is something that is subject to evolution. Miller collects and considers customer feedback, using it to fine-tune headgear offerings that suit the needs of operators. A recent example of that is with the new Legacy headgear. It evolved from favorite parts of the old headgear, complemented with new and improved features.

Solutions to improve comfort and productivity

Operator safety is critical in every welding operation, and employee acceptance of safety gear tends to be better with helmets that are less cumbersome and more comfortable. A helmet that is lighter, cooler and yields a near-custom fit with a quality headgear system will reduce neck strain and lessen fatigue — which makes operators more likely to wear them and avoid the types of injuries that can lead to downtime, time off work and decreased throughput. Finding a helmet that fits means welding operators keep them on more and take them off less, minimizing their exposure to hazards and making for a more comfortable, productive workday.

Understanding the different types of welding helmets is crucial for anyone in our profession. With my extensive experience in fabrication, I’ve encountered various kinds of hoods, each serving SPECIFIC purposes and offering UNIQUE features.

From passive masks, which use a fixed shade lens, to auto-darkening helmets that adjust to the arc’s brightness (power), the range of options can be overwhelming. Each variety has its application for specific welding processes and environments, but not all hoods are suitable for every user.

In this guide, I’ll give you a detailed insight into different helmets for welding with their FEATURES, BEST USES, PROS, and CONS, helping you choose the right one for your needs.

Welding Helmet Types Based On Uses

When you’re in the market for a new welding helmet, sorting them by their intended use can simplify your search. After all, whether a hood is suitable for your needs depends largely on your requirements.

1. TIG Welding Helmet

The problem, however, is that these welding masks detect the amperage of the arc to ACTIVATE auto-darkening. In case the amperage is too low and doesn’t correspond with the lower end of the dark shade range, the hood won’t darken.

This is why low amp (10A to 25A) TIG welding requires you to use special variable auto-darkening helmets that come with an additional shade range of #5 to #9. So, depending on the ampere rating, you may either get a variable auto-darkening helmet with a #9 to #13 dark shade or one specifically made for low-amp welding.

2. MIG Welding Helmet

Once again, a variable shade auto-darkening helmet is your best bet. The standard #9 to #13 lenses should suffice for MIG welding – just make sure that they are of good quality and meet all necessary safety standards.

3. Helmet With Cheater Lens

This is exactly why CHEATER LENSES exist – to magnify the view of your work. You could think of them as a welder’s version of reading glasses – standard lenses designed to improve visibility.

In case you already have a welding helmet, you can upgrade it by adding a compatible cheater lens. However, if you’re planning to buy a new one, why bother with all that hassle when you can simply get a hood with a cheater lens built-in by default?

You can get these styles of helmets at varying prices to suit your budget and requirements.

4. Smart Welding Helmet

I got myself a 3M Speedglas G5-01VC to check out what a Bluetooth-enabled welding hood is like, and it works like a charm. You can use your smartphone to perform a variety of tasks, like adjusting the shades and sensitivity settings, switching between pre-set memory modes, viewing your welding stats, and more.

These types of hoods are still relatively new, and you don’t have a lot of choices. One such smart welding headgear that grabbed my attention was the innovative Xtreme Dynamic Range (XDR) 3D weld visualization helmet.

Here’s why. Developed jointly by Japanese company Kawada Technologies, Inc. and American research center SRI International, it uses high-end cameras equipped with CMOS and IR sensors to improve visibility and perception for the welder.

5. Pancake Welding Helmet

The balsa wood box can be easily sanded and shaped to fit the welder’s face perfectly, leaving no gap for unwanted light to enter and hamper visibility. It also keeps the lens from fogging up, thus helping maintain a CLEAR VISION.

Pancake helmets are very lightweight because they are made of balsa wood and thin metal, making them comfortable to wear. If your job involves working on pipelines for long hours, especially outdoors, getting yourself one of these helmets would be a great idea.

6. Respiratory Welding Helmet

Not only are these powered respirators better at FILTERING out contaminants, but breathing is much easier, too. If you spend hours welding every day, I would highly recommend getting a PAPR helmet.

7. Underwater Welding Helmet

Needless to say, these helmets are solely for underwater welders, such as those working at offshore oil and gas industries, structures, ships, submarines, etc. Their heavy weight makes them an impractical choice for regular use outside of water.

8. Multipurpose Welding Helmet

A multipurpose welding helmet with a grind mode saves you the hassle of changing hoods as you SWITCH between welding and grinding. Considering you won’t have to buy a grinding eye protection separately, it’s also more cost-effective.

Also Read: How Did Welding Hoods Evolve Over The Years?

Types Of Welding Helmets Based On Lens Shade

One of the most crucial factors to consider when choosing a new helmet for welding is the type of lens it comes equipped with. You have three broad options in this regard:

A. Fixed Shade Or Passive Welding Helmet

Fixed shade helmets are best suited for beginners with a tight budget or professionals practicing a specific welding task. Otherwise, consider the following alternatives.

B. Variable Shade Auto-darkening Welding Helmet

Now, when the helmet is in the off state, the default positioning of the polarization filters sets the hood to a PRE-SELECTED darkened shade. This is to protect your eyes in case the lens fails to activate.

Variable-shade auto-darkening welding masks are safer and fairly easy to use – you just have to set the appropriate shade level before you start working.

If you’re looking to get the good stuff right away so that you don’t have to upgrade to a better hood soon, an auto-darkening helmet should be perfect. Unless you just need a hood for simple repairs and DIY fabrications once in a while, it is worth buying.

Also Read: Welding Helmet Shade Calculator

Helmet Styles Based On Face Coverage

With the purpose and lens type addressed, the next consideration is the style of face coverage the helmet provides.

Full-face Welding Helmet

Full-face welding helmets are highly popular among welders and for good reason. I would recommend one unless you are on a tight budget and only need basic face protection for simple projects.

Half-mask Welding Helmet

While full-face hoods can be somewhat stuffy and uncomfortable for extended wear, these half-mask welding helmets offer a great alternative for working in less hazardous environments. I often use them myself for personal projects or when the workshop is less busy.

Flip-up Welding Helmet

However, they are still much more CONVENIENT than regular passive hoods, saving you the hassle of lifting them every time you need to inspect a weld. Underwater welding helmets often use flip-up lenses to allow welders to quickly switch between shaded and regular views.

While these hoods may not offer the same convenience as auto-darkening ones, requiring you to flip the lens up and down between welds, they represent a perfect middle ground between typical passive and auto-darkening helmets, especially if the latter is too expensive for you.

Safety Helmet With Welding Shield

While most welding and fabrication jobs do not require wearing protective headgear with a shield, these are particularly useful in industries such as construction, foundry work, mining, metallurgy, and others where protection from accidental impacts is essential for safety.

Are you interested in learning more about welding face mask? Contact us today to secure an expert consultation!

Types Depending On Power Supply To The Helmet

Back when I mentioned the electronic control unit while describing how auto-darkening helmets work, you must have figured out that they require some sort of a power source. But there’s more! Let’s check out the different varieties of welding masks based on power supply.

Battery-Powered

All auto-darkening helmets require a power source – typically coin batteries. Though not rechargeable, they are pretty cheap to replace. The battery powers up the sensors, the ECU, and the LC-cell filters and enables them to function.

Solar-Powered

Don’t get me wrong – you’ll still need batteries to operate a solar-powered welding helmet. However, the difference is that these hoods don’t rely entirely on batteries. Another misconception is that a solar-powered headgear requires direct sunlight.

The battery initially powers up the helmet, allowing you to begin welding. Once the arc is initiated, solar panels integrated into the gear start generating power by absorbing UV rays from the arc.

This not only harnesses otherwise harmful UV rays but also means you don’t necessarily have to work outdoors when using a solar-powered helmet.

Manual/ Non-powered Helmets

These are simple passive lens welding helmets that have no need for a power supply. All you have to do is bring the hood down on your face, and you’re good to go. While they are pretty safe and easy to use, they come with all the downsides of passive lenses that I mentioned earlier.

Welding Helmet Varieties Based On Material

Moving on, let’s check out the different welding helmet materials that you get to choose from while buying your gear.

ABS Plastic Helmet

These are essentially among the cheapest and most lightweight welding helmets, but don’t let that fool you. Made from high-quality ABS plastic, they are quite sturdy and durable. ABS is a poor thermal conductor, which makes hoods made of this material perfect for typical arc welding.

Leather Welding Hood

Leather is one of the oldest welding helmet materials, still used for its flexibility and excellent resistance to heat and fire. While I would categorize them as hoods or masks rather than helmets, modern leather headgear comes with similar features as helmets made of other materials, such as auto-darkening lenses and flappable panels.

Fiberglass Welding Helmet

Fiberglass is a great alternative to ABS with its excellent insulating capabilities. Compared to ABS, which usually carries a matte finish, fiberglass hoods have a glossy look. The material is SHAPE-RETAINING, offers high tensile strength and does a great job absorbing vibrations.

Fiberglass also works great as a sound insulator, thus keeping out the loud welding noises. Its negligible moisture absorption makes fiberglass welding helmets good for working in humid environments.

Nylon-based Helmet

Among synthetic materials, this is another economical option among welders. While nylon isn’t as strong as ABS, it is much more durable – which means your helmet would last longer unless damaged by HEAVY IMPACT. Nylon is also more resistant to chemicals, which might be something to consider depending on the industry.

Polycarbonate Welding Helmet

Both ABS and fiberglass are great, but polycarbonate offers the best of both worlds. Like ABS, it is highly impact-resistant and is actually the stronger material of the two. Like fiberglass, polycarbonate hoods don’t absorb much moisture.

It can also withstand high temperatures without sustaining any damage. Besides, a lot of welding helmets use POLYCARBONATE LENSES for their superb optical clarity and damage resistance.

Carbon-Fiber Welding Helmet

Carbon fiber is a premium material known for its exceptional strength-to-weight ratio. Helmets made from carbon fiber are lightweight yet incredibly strong, providing excellent protection without the bulk.

The material’s high tensile strength makes it resistant to impacts and vibrations, offering superior durability. Additionally, carbon fiber masks are highly resistant to heat, making them ideal for welding applications where heat resistance is crucial.

Kinds Of Welding Helmets According To The Number Of Sensors

If you’re purchasing an auto-darkening hood, it’s crucial to consider the number of arc sensors it includes. The more sensors your helmet has, the better coverage it provides, ensuring your eyes are protected from flashes caused by out-of-position welds.

• Two Sensor Hoods: These are typically found in hobby-grade helmets, offering sufficient coverage for welding flashes directly in front of you. They are suitable for small DIY projects and repairs.
• Three Sensor Helmets: A professional-grade welding hood should have at least three arc sensors. These are suitable for production work and fabrications where out-of-position flashes are not expected.
• Four Sensor Helmets: I always recommend that everyone in my workshop wears a helmet with at least four sensors. These are ideal for most fabrication and out-of-position welding tasks, providing protection against flashes from other welders nearby.

While some high-end welding helmets come with five or six arc sensors, they are often unnecessary for most welders. However, if it fits within your budget, opting for a headgear with a couple of extra sensors certainly won’t hurt.

How To Tell What Type Of Welding Helmet You Have?

To determine the category of your welding helmet, start by checking its specifications and details on the box, manual, or any documentation provided by the manufacturer. If you received the hood without these documents, you can still identify its lens:

1. Put on the helmet and assess how clearly you can see without welding. If the view is very dark (usually shade #10), it is passive.
2. If the view is only slightly darkened (shade #3), your helmet is auto-darkening.
3. Look for shade adjustment settings. If you can select your preferred shade, it’s a variable shade auto-darkening helmet. If not, it’s a fixed shade hood.

Identifying other aspects like power source, face coverage, and material should be straightforward. With a clear understanding of all categories of welding helmets, a simple inspection should reveal the one you have.

Selecting the Right Welding Helmet for You

So, with such a vast variety of welding helmets to choose from, how do you know what’s most suitable for you? Well, here’s what I personally do – I start narrowing down my options based on the following criteria, ultimately picking a hood that ticks all the boxes.

Welding Application

First and foremost, it’s crucial to consider YOUR INTENDED PURPOSE behind using the hood. As I explained earlier, different welding processes require different helmets. Getting an MIG helmet would be a waste of money if you’re planning to use it for low-amp TIG welding.

Consider factors like the lens type, lens shade/shade range, and amperage to shortlist helmets that would suit the purpose. For special applications and working environments, also consider specialized welding masks like PAPR and pancake helmets.

Light State And Shade of Helmet

I know I just mentioned the shade range, but this crucial factor deserves a special mention of its own. When exploring auto-darkening helmets, check out both the light and dark state shade numbers.

For the former, a lighter state offers better visibility. As for the dark shade, it must correspond with the amperage of your weld. While an insufficiently dark lens won’t offer you enough protection, an excessively dark one would hinder your visibility.

Lens Reaction Time

Auto-darkening welding lenses activate in a fraction of a second from the moment their sensors pick up the weld flash. However, there are still differences, with higher-end welding helmets offering a much faster lens reaction time than cheap ones. The quicker the lens turns dark, the more EFFECTIVELY it protects your eyes.

Sensors, Their Sensitivity, And Delay Settings

Of course, the sensors go hand-in-hand with lens reaction time. While it’s always better to get a helmet with more sensors, you’d also have to balance cost with performance. There’s no need to get one with more than 3 sensors for simple welding projects and DIY repairs. Instead, invest in a hood with superb sensitivity for immediate and accurate flash detection.

Professionals might want to get a welding helmet with delay settings, which essentially allows you to set a delay period during which the lens will stay dark even after you stop welding. This feature is very handy for large fabrication projects where you might need a few moments to reposition for the next weld.

True Color And Optical Clarity

Visibility is a clear factor to consider when narrowing down your options. Unless the lens offers sufficient optical clarity, you’d have a hard time seeing what you’re doing while you weld. Due to the way welding lenses work to filter out harmful UV and IR rays, everything around you would typically be in a shade of low-contrast green when you wear a welding helmet.

However, some brands have come up with modern masks that feature TRUE COLOR technology, which changes the view to a higher contrast that incorporates the rest of the color spectrum.

Viewing Area

While we are talking about visibility, let’s not forget the size of the viewing area. Some helmets only have a relatively small rectangular lens over the eyes, while others have a much larger viewing pane.

For example, in half-mask hoods, you get to see through most of the front part. A larger viewing area enlarges your field of view, which might be helpful in certain welding and fabrication projects.

Face Coverage

Considering the whole purpose of a welding helmet is to protect your face and eyes, let’s not forget face coverage. While I’d usually recommend a full-face hood, other designs with smaller coverage might be fine, depending on your requirements.

Depending on the industry and safety requirements, you may also consider getting a safety helmet with a welding shield.

ADF Power Requirements

If you’re getting an auto-darkening mask, would you rather choose a solar-powered hood or a battery-operated one? While the former comes with a higher price tag, it can save you money on batteries in the long run.

Material And Durability

Generally speaking, most of the welding helmet materials I mentioned earlier are pretty durable and can be used in most environments. Consider criteria such as comfort, cost, durability, insulations, and specific characteristics to choose a hood that offers the best value for money.

Among these, durability is a particularly important factor as your chances of needing a new helmet anytime soon depend on it.

Special Features

With the basics covered, you can now look for special features like Bluetooth connectivity and a Camera. These aren’t absolutely necessary for most projects, but you may consider getting a welding helmet with such features for specialized welding work or simply for the sake of convenience.

Comfort And Fit

Now that your options are down to a select few, put on the different helmets and compatible accessories to see which ones fit the best and make you most comfortable. Remember, even small elements that influence your comfort can make a huge difference when welding for extended periods.

Price

Lastly, consider the price of the masks to pick one that suits your budget and offers good value for money. You can easily find a welding hood for under $50 and up to $, depending on the features and build material.

Investing in a top-notch hood is always worth it, considering it’s a matter of safety. However, if you are a hobbyist or simply want to carry out small repairs, there’s no need to spend on an expensive professional-grade welding helmet.

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