Tips to choose the right welding helmet - Canadian Metalworking

With more new welders entering the workforce, it’s essential to understand what goes into selecting a welding helmet. Not all helmets are created equal, and their style, features, and price points often reflect that.

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But with so many different helmets available, how do welders choose the right one that will stand up to their requirements?

Some companies may purchase welding helmets and starter kits, which includes all safety gear, as a perk for new employees, while others may look to have their welders using high-end equipment to entice welders to join the company. Regardless of how a welder comes to possess the helmet, it must meet specific criteria.

Frequency of Use

The first question that needs to be answered when exploring welding helmets is just how often the welder will be using the helmet. A hobbyist welder will use the helmet far less frequently than a professional welder who works eight-hour days, five days per week.

“A hobbyist welder may not need a helmet with all the bells and whistles, and you can get a decent helmet for a few hundred dollars,” said Andrew Newman, welding applications technologist, Fronius Canada Ltd., Mississauga, Ont. “On the flip side, helmets can range all the way up to powered air purifying respirator (PAPR)-style helmets, which can be thousands of dollars. But then there is everything else in between.”

The needs of a part-time welder are different from those of a professional welder, and choosing a helmet that can meet potential future needs is also an important consideration, especially for someone new to the industry.

Various Applications

For those who are welding for the first time or starting a new job, it’s important to understand what they will be doing on a daily basis.

“What type of welding processes will you be doing?” said Kevin Beckerdite, global product manager – PPE, ESAB, Mississauga, Ont. “A lot of new welders start off with stick welding. But it’s important to consider that there are so many different products on the market ranging from the very basic, old-school passive welding helmets all the way up to very sophisticated autodarkening welding helmets.”

Whether it’s stick, MIG, TIG, or another welding process, the general amperage range will help determine the helmet shade requirements.

Most helmets have a basic shade range of nine to 13, whereas some can go as low as two and all the way up to 14. Depending on the type of work, the shade range needed will change. For example, TIG welding thin stainless steel will require a helmet that has a sensitivity on the low end of the range while heavy-deposition or flux-cored welding, where there is an extremely bright arc, requires a lens shade of 12 or 13.

“Some of the cheaper options tend to have tighter ranges, which can be limiting,” said Newman. “Look for a helmet with an extended range to give you that flexibility. Will you be doing grinding? Look for something with a grind mode feature so that the helmet’s use is expanded.”

Autodarkening filter (ADF) helmets provide shade options, meaning they can be used for a variety of welding operations. This provides users with the flexibility to do entry-level work to more advanced MIG and TIG welding operations.

“ADF helmets are great because they don’t require the user to lift up and down the hood, meaning that during welding activities, they can be focused on the weld rather than taking their hands off the tool to adjust the helmet,” said Beckerdite. “If there is a lot of finish work along with welding, like grinding the welds, there are available face shield options so that the user doesn’t need to take the helmet off to get that clear view of the work area.”

Lens Considerations

When it comes to lenses, optical clarity is essential for professional welders where quality is key.

“When choosing a welding helmet, one of the most important considerations should be the type of lens,” said Mike Clifford, product manager, welding gear and tools, The Lincoln Electric Co., Cleveland, Ohio. “There are two types of lenses to consider, passive and autodarkening. Autodarkening is the preferred lens type because they provide greater versatility along with increased productivity, which are important benefits to welders.”

There are four classes of optical clarity which are generally rated from one to three – with one being the best and three the worst. The different class ratings should coincide with the needs of a welder.

“For example, not all welders will need a top-rated helmet,” said Newman. “But if it’s meeting all the characteristics you want to get out of it, then that is the right helmet. Do you need true colour? Or is the colour being distorted? For those that are just learning, having higher and clearer image quality can be advantageous.”

Some lenses offer panoramic views, providing the welder with a wider viewing area while limiting the number of times the helmet needs to be flipped up and down. The helmet also could have a shade as low as 2.5 to allow the welder to see through it clearly without needing to flip it up.

“A lot of welders are dialing in to larger viewing areas,” said Beckerdite. “This is especially true for more experienced welders, where they want to see what's coming in front of the weld, the active weld that they're working on, as well as what’s already been welded.”

ADF helmets allow for the welder to dial-in to precision welding. Choosing a helmet with true colour capabilities, especially when its in the passive state, can really help with overall welder performance.

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“Being able to watch the weld pool colour is extremely important to determine the weld quality,” said Beckerdite. “The clearer the view is, that matters with the welders when they're working on high-quality welds; they watch the pool and the heat, the hotness of it changes the colour. When you have a welding helmet [with a lens] that has a weird tint on it, you are not actually getting the true colour of that weld puddle. Lens clarity is key.”

Added Comfort

Most welders want a helmet that feels lightweight and comfortable. The headgear shouldn’t create hot spots or pressure points on a welder’s head. If it isn’t comfortable, that could potentially discourage welders from wearing it. A helmet that is comfortable and it won't fatigue the body over the course of the day will encourage proper usage.

The helmet itself will always have some weight to it, but the goal is finding one that is well-balanced over the welder’s body.

“There's a range of styles of headgear in the market, anywhere from the simplest version, which might be a three-point headgear up to a six-point pivot headgear, to create a personalized fit,” said Clifford.

A welder carries the helmet’s weight across the neck, shoulders, and body, which can put a strain on those areas over time. A customizable helmet can help adjust the load based on personal needs.

“Headgear and the way the helmet fits to the user's head has come a long way,” said Beckerdite. “They are adjustable on several different planes and axes. The user can customize the fit as closely to the head as needed. The types of materials used in headgear has changed a lot. There are less stiff, uncomfortable headbands to much softer, pliable material that really conforms to the head.”

Beyond the standard welding helmets, those working with PAPR units need to think about how the system sits on their body.

“Some are styled with a belt buckle, where a fan and filtration unit sit on the wearer’s lower back,” said Newman. “Others now have shoulder straps that redistributes the weight more evenly.”

Personal protective equipment (PPE) should essentially feel like it disappears on the user's body, whether it's a helmet, gloves, or another type of equipment. It shouldn’t distract from what the welder is trying to do.

Smart Technology

The latest advanced technology can make the work of any welder that much easier. Helmet manufacturers are constantly finding new ways to make helmets easier to use while increasing weld quality.

“Arc tracking is very popular right now,” said Clifford. “This smart technology is built into the helmet to track welding throughout the day, identifying the welder’s arc-on time. This is great for calculating productivity and identifying areas of improvement.”

Smart technology also allows welders to save different mode configurations in the helmet’s memory that they prefer to use or have worked well. This eliminates the need for the welder to set everything up each time.

“Bluetooth connection is also something big right now,” said Newman. “Traditional ADF helmets have sensors in them that pick up light and switch the helmet over to dark mode. This can take 90 to 100 microseconds (µs), leaving a slight delay in switching over, and it's dependent upon seeing that light through the sensors. Some helmets will have only one or two sensors, and more advanced may have five or more. The Bluetooth function means that when the welder pulls the torch trigger, the helmet automatically adjusts. There's no delay time, and it will stay on continuously during the welding process until they stop. So that eliminates mode changes due to sensor blockages.”

Safety Enhancements

When it comes to safety, the good news for every welder is that there are workplace requirements that dictate to welding PPE manufacturers the safety standards these devices need to meet. The Canadian Standards Association (CSA) is one organization with rigorous safety standards. It requires that all welding helmets include a CSA Z94 mark indicating it is in compliance with the safety standard.

These standards are designed to make sure that, regardless of the task, workers have proper protection from any potential hazards, meaning protection of the eyes, face, neck, and ears.

Beyond the regulations, some welders may want to upgrade to more advanced systems like PAPR helmets, which are becoming increasingly popular, in Canada.

“Even for the most basic applications in steel welding, the regulations for the threshold limit values for things like manganese have reduced to the point that having a respirator-style helmet or some sort of fume extraction in the area is a must-have nowadays,” said Newman. “There are different ways to upgrade for additional safety. Adding a bib to the front of the helmet can protect the welder from light coming up from underneath the helmet. Talk to any helmet manufacturer and they can help identify ways to make welding safer for the welder.”

Associate Editor Lindsay Luminoso can be reached at [ protected].

ESAB Welding & Cutting Products, esab.com/ca

Fronius Canada, www.fronius.com

Are you interested in learning more about ppe safety gloves? Contact us today to secure an expert consultation!

I'm looking for a new auto-darkening welding mask as I'm getting fed up with my current one that performs very badly during certain light conditions.

Budget is about £100

Occasional home use.

MMA welding and a bit of grinding.

In another thread the Parweld XR938H was suggested as a possible option. They cost £61.50 on eBay so well within budget. One reviewer mentioned the mask was almost too small (60 cm head) which makes me think it may be unsuitable (62 cm head size) especially if I wear a cap in winter. Any thoughts on this?

I've also seen ESAB Savage A40 for just under £90. I don't know how that compares size and quality wise.

Thanks.

ESAB Savage A40 True Colour Auto Darkening Welding Helmet - Free P&P* | eBay

Find many great new & used options and get the best deals for ESAB Savage A40 True Colour Auto Darkening Welding Helmet - Free P&P* at the best online prices at eBay! Free delivery for many products.

Parweld XR938H red shell large view 5-13 shade auto welding & grinding helmet | eBay

Find many great new & used options and get the best deals for Parweld XR938H red shell large view 5-13 shade auto welding & grinding helmet at the best online prices at eBay! Free delivery for many products. Just to satisfy my curiosity (not intention of buying) does a much more expensive mask have any genuine benefits for an average / occasional user who only MMA welds? (I had a brief go with MIG welding a while back but ended up ditching the welder).

ESAB SENTINEL A60 AUTO DARKENING HELMET FREE P&P* CHEAPEST ON EBAY | eBay

Now you’ll have an even wider view of the weld pool without any distortion. Since Sentinel A60 was built with better vision in mind, you’re going to love what you see. With Sentinel A60’s signature shell design, you’re the only one who won’t notice you’re wearing it. I bought an Optrel Crystal - after quite happily using a GYS Alien for over a year with usage of 2-3 days a week. The Optrel is well worth the money, not just in terms of enabling better visibility of welds but also in reduction of eye fatigue. Most of my welding is TIG, with some MIG/MAG and a small amount of MMA.

I bought an Optrel Crystal - after quite happily using a GYS Alien for over a year with usage of 2-3 days a week. The Optrel is well worth the money, not just in terms of enabling better visibility of welds but also in reduction of eye fatigue. Most of my welding is TIG, with some MIG/MAG and a small amount of MMA.

Thanks, but if I've found the right one, the Optrel is signficantly beyond my budget.

Optrel Crystal 2.0 True Colour Auto Darkening Welding Helmet

Crystal lens technology Shade 2 natural state Grind mode Shade range 4-12
The GYS is within budget

GYS Alien True Colour Automatic Welding Helmet XXL Screen - Lincweld

The GYS Alien TrueColor helmet removes the green tint from the welders view, creating near perfect visibility of the weld piece. The GYS is good, just not 'Optrel good' but you did say 'just to satisfy your curiosity'
TBH, if I hadn't borrowed an Optrel for a one-off urgent job from a mate nearby (along with his TIG set), I'd be more than happy with my GYS Alien, which I still have for use at work - I only use it for ~10% of my welding now I have the Esab A40 and I feel grateful to have it every time I use it. Unlike my old lid, where I had to position my head to be able to even see what I was welding, the Esab just works without thought or effort. I just flip it down and get on with it. It's the most comfortable lid I've worn and great vision. I have got two Parweld XR938H helmets.
One for me, one for my 7 year old lad. I like them, that being said, I have not had any more expensive helmets than the Parwelds. I feel they are good value for money / good price performance ratio.

I also have an Esab Warrior Tech helmet which I got as part of a job lot in an auction recently, I have not tried it yet but it looks like it has been replaced with the Esab A40.

Just to satisfy my curiosity (not intention of buying) does a much more expensive mask have any genuine benefits for an average / occasional user who only MMA welds? (I had a brief go with MIG welding a while back but ended up ditching the welder).

ESAB SENTINEL A60 AUTO DARKENING HELMET FREE P&P* CHEAPEST ON EBAY | eBay

Now you’ll have an even wider view of the weld pool without any distortion. Since Sentinel A60 was built with better vision in mind, you’re going to love what you see. With Sentinel A60’s signature shell design, you’re the only one who won’t notice you’re wearing it.

As an occasional mig welder with both an Optrel Welding Cap and a Panoramaxx CLT Auto I’ll never get a return on them with the amount of welding I do but they sure as hell make welding easier when you can clearly see what your doing.
My previous helmet was a Clarke auto darkening and the difference was literally night and day.

BTW the Optrel Welding Cap was free (it had never been out the box) with a second hand welder I bought. I thought it was a cheap Chinese gimmick but was surprised it was worth more than the welder.

. One reviewer mentioned the mask was almost too small (60 cm head) which makes me think it may be unsuitable (62 cm head size) especially if I wear a cap in winter. Any thoughts on this?

You can usually change out the head cage from the helmet to swap for another so can probably use your old one in the new helmet if need be.
Optrel ISOFIT headgear is around £60 but makes great fit even for the biggest and/or odd shaped head.

I have got two Parweld XR938H helmets.

I have the Parweld as a "visitor helmet"....the optics are pretty good...not quite as good as my 3m setup but it's pretty close and for the money can't really complain.

I find the true colour ones are a lot better in terms of visibility so whatever you buy I'd say make sure its true colour (vs the old green filter)

Thanks for the replies everyone.

I've ordered an ESAB Savage A40 £93.89

This was the best price I could find for a registered business seller and not an eBay "private" seller that would probably lack a warranty.

Received yesterday, giving it a quick try this evening.

Seems ok so far. Shade appears to work as it should. The mask itself is quite small (for a larger head) and I have the headgear set on maximum, less one click. There won't be any opportunity to wear a hat when it gets colder. Generally happy.

Spent a while using the esab a40 this evening. Arc welding, as that's all I do at home.

It's clearer than my old (cheap) helmet and reacts well to the arc. The true colour thing doesn't make any difference to me. The grind button is useful to have.

It's an improvement over what I had. It's not a game changer but may give me a chance of improving my welding. Hello! I've been doing a lot of welding on my 100E lately. I decided to buy a new helmet and went for one from Screwfix. It was an Impax IM-AWH-800D I liked it but it started playing up after a few days. They replaced it and the new one did the same. It was £49.99. I got a refund. I read this thread and bought a Parweld XR938H. It was about £62. I just wanted to say I am very pleased with it and the whole feel of it is better than the Impax. It feels more rugged and less fragile. It is also quite compact. So I just wanted to say thanks to those that mentioned the Parweld, and say that it seems pretty good if on a limited budget. Mart.