Advancements in the world of welding have been many in the last couple of decades, but one that stands out the most when it comes to convenience is the auto darkening helmet. While the visor of a welding helmet is mainly operated by hand, having a sensor do the job for you is much quicker and easier. Although the sensor requires power to function, you don’t need to worry about forgetting to flip down the visor. As long as you’re wearing the helmet, the lens will react automatically when welding starts.
What Matters?
Viewing Area
The size of the helmet’s viewing area can have a significant effect on how easy and comfortable it is to use. The larger it is, the less you need to move your head and strain your neck. The trade-off is that larger auto darkening lenses are more expensive to manufacture, which can increase the overall cost of the helmet. Usually, a modern welding auto darkening helmet has a viewing area of around 98 x 88 mm, with the industry-standard size being 100 x 90 mm.
Reaction Speed
The speed at which the sensor is able to detect the arc and darken the visor is referred to as reaction speed. The quicker the sensor detects, the quicker it reacts, with most helmets able to respond in 0.04 to 0.1 milliseconds. Those meant for professional use typically have quicker reaction speeds than entry-level helmets.
Sensor Configuration
The number of arc sensors in a welding helmet can affect reaction speed. Usually, more sensors provide better coverage and reduce the chance of the arc being blocked from view. However, sensor quality and placement are just as important. In some cases, a well-designed helmet with two sensors can perform just as well as one with four.
Safety Certifications
As an essential piece of welding equipment, a welding auto darkening helmet needs to be more than convenient. It also needs to be safe, so the helmet should meet all relevant safety standards and certifications, including AS/NZS 1337.1:2010 and AS/NZS 1338.1:2012. The former is for the frame and lens construction, and the latter is for the performance requirements of the filter lens.
Power System
There are two main ways a self-darkening welding helmet can be powered: solar power with lithium batteries or replaceable batteries. The former is more versatile, as you can use the helmet outdoors without charging and indoors by charging it overnight. The latter is more convenient as you only need to swap the batteries when they run flat.
Ergonomics
Some helmets come with moisture-wicking straps and memory foam headgear for added comfort. The most important factor is fit and balance. It should feel comfortable to wear for extended periods without causing strain or distraction.
Environmental Resistance
Since it’s a welding helmet we’re talking about, it should not only withstand spatter but also resist high temperatures. The former requires a flame-retardant shell and an anti-glare coating, while the latter depends on the helmet’s specified operating temperature range.
Optical Clarity
It’s not just the size of the viewing area that matters in an auto darkening helmet, but also its optical clarity. This is rated on a scale from 1 to 3, where 1 is the highest quality and 3 is the lowest. The rating covers distortion, shade consistency, blurriness, and angle dependence. A 1/1/1/1 rating indicates the highest possible level of clarity across all four categories.
PAPR
You can get an auto-darkening welding helmet that works together with a PAPR unit. A powered air-purifying respirator delivers fresh air to the helmet, so your respiratory system is also protected from the fumes produced by the welder. This way, you have double the protection with one piece of equipment.
Weight
The weight of the helmet determines its ergonomics, alongside the size of its viewing area. The heavier it is, the more cumbersome it is to wear, especially when working on more demanding projects. Most helmets nowadays weigh between 380g and 500g. Keep in mind that a heavier auto darkening helmet doesn’t always mean better protection, either, as lighter models can be as protective as their heavier counterparts.
Fixed vs Variable Shade
There are two types of lenses a self darkening welding helmet can have: fixed and variable shade. A fixed shade lens always darkens the visor to a predetermined level, which can be quite limiting when working across different types of welding processes. A variable shade lens can adjust to different levels depending on the task, or you can manually set the shade if it’s too light or too dark.