During MIG welding, the electric arc emits light identical to that of the sun. Without a special protective helmet, all welders would get light burns on the skin and the cornea of their eyes. Thanks to this shade lens accessory, you can protect your face and head from UV rays and dross.
How to choose a MIG welding helmet
Modern helmets have a great variety of prices, quality, and shade lens.
In order not to overpay, but also not to buy a second-time protective device already in half a year, it is worth understanding the key characteristics of a MIG welding helmet and choosing the most suitable for a particular activity.
Working principle and construction of a helmet
For more than one hundred years, designers have been working on improving the shape and functionality of the MIG welding helmet and shade lens
A MIG welding helmet with a shade lens is designed to protect the worker from a number of harmful factors:
- The electric arc emits ultraviolet light and a large amount of heat, which harms the welder’s skin.
- Constant observation of weld formation can lead to severe corneal burns and blindness.
- During metal melting, some impurities are likely to release and bounce off in the form of burning dross.
- The melting electrode and the edges of the welding surface emit toxic fumes that are necessary to protect the weld pool from the outside environment. Inhaling such fumes is also dangerous.
That is why for more than one hundred years, designers have been working on improving the shape and functionality of the MIG welding helmet and shade lens, intended to protect the specialist from this range of negative factors.
Also, the accessory with a shade lens on the head completely frees the hands so that the welder can independently hold the item and weld it with the electrode in the second hand. This increases productivity and reduces the number of people involved in one process.
People use helmets with shade lens everywhere: in factories, service stations, repair shops, and in the private sector when working in the cottage (setting up fences, gates, and shower tanks).
A wide variety of prices allows everyone to purchase this accessory with lens shade, even if you have to weld once a year.
Most types of helmets include the following elements:
- a hood with an elongated part to protect the neck and a semicircular notch at the top for free lifting;
- viewing window with a shade lens for observing the process and preventing UV rays;
- a light filter that protects against bright flashes;
- solar panel for recharging batteries from the arc light (for auto-darkening helmets);
- dimmer control of the light filter;
- head mount lock.
The light filter, the main protective element of the helmet, is a black-coated glass, called passive welding lenses. In daylight, it is impossible to see anything through it. But when the welding arc ignites, the edges of the welding metal and the melting point of the electrode become clearly visible.
Depending on where the work is done, the shade number varies.
Some models have a hinged window that allows you to lift the shade lens and look at the weld without removing the entire helmet. This improves performance a bit and makes it easier to use. But such helmets weigh more, which increases the strain on the neck.
Other models, called auto-dark welding helmet, have a light filter made of two panes of glass with liquid crystals in between. Normally, they are perpendicular to the plane and allow the welder to see what is going on. But at arc ignition, the crystals rotate 90 degrees, which darkens the shade welding lens to the right level, and now you can see only welding through it.
Pressed cardboard or heat-resistant plastic can be the material for the helmet. Manufacturers can paint them bright yellow and red. It promotes more light reflection and also makes the welder more visible to crane and bridge hoist workers.
Types of MIG welding helmets
Depending on the required safety and convenience of the work, there are different types of MIG welding helmets. You can learn more about how they work in this article.
Passive welding helmet
Pressed cardboard or heat-resistant plastic is the material for these passive helmets. Paper models are much lighter than plastic ones.
Most welding helmets of this type have a small viewing window with a passive welding shade lens and a budget mount without a soft backing.
To change the passive helmets lens shade number, you need to remove the accessory from the head, unscrew the block lock and replace the shade lens with an element with a larger value.
Such passive helmets are cheap and suitable for novice welders.
Advantages:
- cheap;
- cardboard versions are lightweight;
- protection of the lens shade at the proper level;
- you can work at any air temperature;
- there are models with wide viewing windows.
Disadvantages:
- plastic models are heavy;
- the cardboard helmet can swell from moisture;
- the head mount is hard;
- there are very large hoods that are inconvenient for MIG welding in hard-to-reach places.
Auto dark helmet
Crystals in the auto-darkening helmet make the auto-dark lens transparent after the arc interruption.
The auto-darkening helmet contains a liquid crystal screen.
It is convenient that the welder does not need to constantly lift the auto-dark helmet up after each weld to assess the quality of work and see where to start the next joint.
Crystals in the auto-darkening helmet make the auto-dark lens transparent after the arc interruption.
To adjust the auto-dark lens shade, just twist the switch of auto-darkening on the left side of the helmet, which you can do even without interrupting the arc.
The auto-darkening operates from the battery and is powered by the light of the MIG welding.
Auto-darkening is convenient for those who perform many small welds and who need to move around the item often. This type of welding safety equipment is especially popular with argon welders.
The auto-dark lenses allow for quick operation.
Advantages:
- cheap;
- cardboard versions are lightweight;
- protection of the lens shade at the proper level;
- you can work at any air temperature;
- there are models with wide viewing windows.
Disadvantages:
- plastic models are heavy;
- the cardboard helmet can swell from moisture;
- the head mount is hard;
- there are very large hoods that are inconvenient for MIG welding in hard-to-reach places.
Helmets with forced air supply
Sometimes MIG welding work takes place inside an enclosed space
Gases from the molten electrode and the workpiece are escaping into the air during MIG welding.
Normally, it is sufficient to have an extractor hood above the workplace to remove harmful fumes. But sometimes MIG welding work takes place inside an enclosed space. Then it is necessary to use a helmet with a forced air supply to the respiratory organs.
It works on the principle of a respirator, which is attached to the back of the worker. A small electric motor draws in ambient air, filters it through a protective system, and feeds it through a hose directly under the helmet.
This design requires additional equipment but allows for safe operation in specific conditions.
Advantages:
- reliably protects against harmful gases;
- allows you to work in difficult technical conditions;
- has good lenses;
- high visibility of the viewing window;
- easy adjustment of the mount;
- large range of shading values.
Disadvantages:
- high cost;
- it is possible to catch the hose on protruding objects;
- some models have a high top spigot, which creates additional difficulties for work;
- additional costs for filters and batteries.
MIG welding helmet selection parameters
A MIG welding accessory has many selection parameters that determine where you can use it and how comfortable it is for the welder. To buy the most suitable helmet, you need to consider the criteria below.
Viewing window size
The screen of the MIG helmet determines how well the welding pool will be visible to the specialist.
For those who work in the lower position and have the opportunity to look directly at the MIG welding area, a small viewing window is sufficient.
Workers who have to weld pipes close to the wall or floor will need a larger screen.
Those who constantly work inside large pools or with overhead welding require a vertically enlarged window. With a small screen, you will have to twist more with your neck, and because of the limited space, it can be difficult, and your muscles get tired quickly.
Shading
In auto-dark helmets, the scale of darkening denotes in DIN and comes in a range from 5 to 15. Since these helmets have an adjustable degree of crystal turning, it is necessary to choose an accessory with a range of 9-13.
The upper values will be enough to work on the street, and the lower values are enough for the shop or garage. Use readings from 5 to 8 DIN in very dark environments or in case of poor vision.
Weight
Often professionals lower the helmet with a sharp nod of the head because the hands are already busy
A MIG welding protective accessory’s weight can vary. The type of cover material, the thickness of the glasses used, the mounting and additional accessories influence this. The lower the weight, the more comfortable the welder is.
It will also reduce the negative load on the cervical vertebrae because often professionals lower the helmet with a sharp nod of the head because the hands are already busy.
But this is all important for professional use. In the case of private use and welding work once a month, any helmet will do.
Type of filter
Passive welding lenses are good for arc welding with fusing electrodes because of a cheap protective glass cover for frequent replacement, due to the splashing of slag on its surface. This is a good option for the beginner or in the case of cottage use.
Welders engaged in argon welding machines should choose auto-dark helmets with liquid crystal screens. Such a helmet increases productivity, helps you quickly change the welding area without removing the accessory, and allows you to precisely start a new weld without unnecessary traces of the arc.
Auto-darkening
When the arc ignites, the crystals must turn around instantly and manage to protect your eyes from the bright light.
You can only check this parameter personally by turning the filter on the weld or the bright sun. If the eye has time to see the light, it is a bad helmet that will ruin your vision.
What shade lens for the MIG helmet to choose?
Material: Mild steel – Type of welding: MIG – Amperage: 80-100 Amps – Lens shade: 10
Material: Mild steel – Type of welding: MIG – Amperage: 100-175 Amps – Lens shade: 11
Material: Mild steel – Type of welding: MIG – Amperage: 175-300 Amps – Lens shade: 12
Material: Mild steel – Type of welding: MIG – Amperage: 300-500 Amps – Lens shade: 13
Material: Aluminum – Type of welding: MIG – Amperage: 80-100 Amps – Lens shade: 10
Material: Aluminum – Type of welding: MIG – Amperage: 100-175 Amps – Lens shade: 11
Material: Aluminum – Type of welding: MIG – Amperage: 175-250 Amps – Lens shade: 12
Material: Aluminum – Type of welding: MIG – Amperage: 250-350 Amps – Lens shade: 13
Material: Flux core – Type of welding: Flux core – Amperage: 125-175 Amps – Lens shade: 10
Material: Flux core – Type of welding: Flux core – Amperage: 175-225 Amps – Lens shade: 11
Material: Flux core – Type of welding: Flux core – Amperage: 225-275 Amps – Lens shade: 12
Frequently Asked Questions
In this article, we covered the basic parameters for choosing a helmet. Nevertheless, if you still have questions, you can study the answers to the most frequent inquiries from novice welders.
What shade should I MIG weld at?
For MIG welding, you can choose lens shades 10 to 13, depending on amperage. In most cases, you should not choose the darkest shade welding lens.
How dark should I set my welding helmet?
Pay attention to the type of welding and working conditions. In the case of MIG welding, choose welding lens shade number 10 to 13, depending on amperage.
What lens shade should I use for welding mild steel?
Often, workers need to perform welding work on mild steel. If you are working with mild steel, pay attention to the following parameters:
Material: Mild steel – Type of welding: MIG – Amperage: 80-100 Amps – Lens shade: 10
Material: Mild steel – Type of welding: MIG – Amperage: 100-175 Amps – Lens shade: 11
Material: Mild steel – Type of welding: MIG – Amperage: 175-300 Amps – Lens shade: 12
Material: Mild steel – Type of welding: MIG – Amperage: 300-500 Amps – Lens shade: 13
Conclusion
Welding helmets with active light filters are gradually becoming cheaper and replacing traditional passive helmets. At the same time, the quality and functionality of the products are constantly increasing. Perhaps the time is not far off when welding machine manufacturers will equip their machines with simple auto-darkening helmets.
