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Common Welding Helmet Mistakes & How to Choose the Right One
A welding helmet is an essential part of your protective equipment, and it's a must-have for anyone getting into a trade. A good welding helmet will protect your face and eyes on every occasion, but mistakes happen, and you can get flashed.
Common welding helmet mistakes include disregarding comfort and fit, using the wrong settings, and working with worn or damaged parts. All of these can cause helmet failure or malfunction, potentially damaging your eyes.
We compiled this article to highlight common welding helmet mistakes and help you choose the right one for your applications. Without further ado, letโs make your welding safer.
5 Common Welding Helmet Mistakes and Troubleshooting
Welding helmets are essential components of welding protective equipment. They protect your eyes and face from intense light and your neck from burns.ย
While most helmets will do their job, choosing the wrong ones can be hazardous. Poor-quality helmets can break apart or occasionally flash you.
Nonetheless, arc flash is not the only issue. You can do several things wrong when using and buying a welding helmet. Understanding these is crucial in addressing the problems, so letโs learn more.
Source: https://www.youtube.com/watch?v=Z3kWBVcoWso
Ignoring Welding Safety Standards
One of the biggest mistakes you can make when choosing a welding helmet is failing to check safety standards. All helmets must meet the ANSI Z87.1 American National Standard for Occupational and Educational Personal Eye and Face Protective Devices.
The American National Standards Institute (ANSI) compiles standards that each helmet must pass to be considered safe for use. These include impact resistance (high mass/velocity), optical clarity, and specific hazard protection (dust, splash, radiation).ย
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Improper Helmet Fit and Discomfort
Many welders overlook fit and comfort when buying a welding helmet. Arc radiation (UV/IR rays), heat, sparks, and spatter will burn any exposed skin, and your head is first in line. A good welding helmet must completely cover your face and neck.
When it comes to fit and comfort, headgear plays a crucial role. Adjustable headgear will help you achieve a perfect fit, regardless of your head shape and size. The key is to find a snug yet comfortable fit for your helmet.
Adjust the Headgear for the Perfect Fit
Source: https://www.youtube.com/watch?v=5vq35nAZiEk
A welding helmet shouldnโt feel clunky. If it tilts and slips as you move your head up and down, youโll have to adjust the headband for a better fit. Otherwise, youโll experience intense neck fatigue over prolonged periods.
Proper weight distribution is crucial in avoiding neck strain. Heavy, front-loaded helmets can cause severe strain, especially if you spend an entire shift under a hood.
Wear the Proper Helmet for Safe Welding
Photo by @haydenjohns18 (TikTok)
Incorrect Helmet Settings
Auto-darkening helmets have three basic settings:
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Sensitivity
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Shade
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Delay
Getting one of these wrong can cause an arc flash, eye strain, or damage, so be cautious. Here is a brief explanation of how each affects the helmet's performance.
Arc Flash During Welding
Photo by @13_alejandro_ (TikTok)
Sensitivity: This parameter adjusts how much light triggers the auto-darkening function. High sensitivity will make the helmet darken even in minimal light, such as a lightbulb or a low-amp arc. Low sensitivity will trigger auto-darkening only in response to intense light from a high-amp arc. The key is to set the sensitivity to turn your helmet on only when you start an arc, not on the shop light, your fellow welderโs arc, or at all.
Shade: Shade settings dictate how dark the lens will get. Auto-darkening helmets typically include welding shades #9-#13, and the choice depends on the project. Lower shades are better suited for low-amp applications, while higher shades are better for high-amp processes. If the shade is too high, you wonโt see a weld. If you set it too low, you risk damaging your eyes.
Delay: This parameter controls how long the auto-darkening lens stays dark after the welding arc stops. A higher delay is useful when welding thicker metal, as the heated surface can still emit radiation even when the arc stops. Low delay is better for quick work, such as tack welds. Getting the delay wrong can cause severe eye fatigue.
3 Basic Settings of Auto-darkening Helmets
Welding Without Testing the Helmet (Auto-darkening Failure or Flicker)
Your welding helmet can flicker or fail completely, even if you set all the settings correctly. In most cases, the cause is worn-out or poorly installed batteries.ย
If there are no solar cells, batteries are the primary power source in your helmet. Dead batteries will cause occasional flickering or prevent the ADF from turning on. Luckily, most modern helmets have a flashing low-battery indicator, so youโll know whatโs up before you damage your eyes.
Flashing Low-Battery Indicator on the Helmet
The best practice when changing batteries or buying a new helmet is to test it first. Many newer helmets have a test button, but donโt worry if yours doesnโt. You can test it by adjusting the sensitivity and then looking at a bright light source (e.g., the sun, a phone flashlight, a lightbulb, or even a TV remote that emits IR). Testing is much safer than being unpleasantly surprised if the ADF fails once you light up the arc.
Another common cause of ADF failure or flickers is dirty or blocked sensors. Number and sensor position matter, particularly if you work in cramped or uncomfortable positions. Debris or weldment parts can block sensors, rendering them unusable. Additionally, dirt can cover the lens and sensors, preventing ADF triggering or causing visibility issues.
Ignoring Regular Maintenance and Care
Like any piece of equipment, your helmet requires periodic maintenance and regular care. Ignoring it is a common mistake many welders make, especially hobbyists who donโt use helmets too often.
As a regular maintenance, you should visually inspect the helmet for signs of damage, cracks, dirt, or scratches on the front cover lens. A damaged helmet can leak radiation, and it is never a good idea to use one.
Inspect the Helmet for Visible Damage
Source: https://www.youtube.com/watch?v=sZPJcbcDHSY
The cover lens protects the inside filter lenses, but it wears out over time. Dirt, cracks, scratches, or damage can affect visibility and sensor response, so make sure to replace them. Periodically wipe the protective lens with a microfiber cloth to remove dirt that can affect its performance.
Donโt forget to remove the protective film from the lens. This film protects the front lens from damage during transportation and storage, but it can affect visibility and sensorsโ response if left on.
Remove Lens Protective Film
Source: https://www.youtube.com/watch?v=sZPJcbcDHSY
If you donโt have the low-battery indicator, periodically check and replace batteries. Replacing them before they start to fail will keep your eyes safe. Be sure to install the batteries correctly, and donโt forget to check the surfaces and contacts.
Also, check the headgear, as it wears out too. If the helmet starts to feel loose or flimsy, and tightening it doesnโt help, youโll have to replace the headband.
Check the Headgear
Source: https://www.youtube.com/watch?v=sZPJcbcDHSY
Buying a Helmet Based on Its Price
Many welders pick a helmet solely based on its price. In reality, your goal should be to buy a helmet that suits your needs, rather than choosing the most expensive or the cheapest option available.
Indeed, costly helmets often provide better build quality, visibility, and lower weight. For example, state-of-the-art helmets have fast reaction time and low-amp detection. You can wear them all day without feeling exhausted, but do you intend to? If you are a professional welder working 8-10-hour shifts, often using TIG, a top-notch helmet should be a priority.
TIG Welding with a High-Quality Welding Helmet
Source: https://www.youtube.com/watch?v=P9HPvW9BrUw
However, if you are a hobbyist or home welder who runs a few beads a week, investing in an expensive helmet is relatively inefficient. Nonetheless, you still shouldnโt pick the cheapest option available. Cheapest helmets often lack optical clarity or auto-darkening reliability.
Saving bucks on protection can cost you your eyes, so to keep yourself safe, we recommend browsing the YesWelder helmets. These feature-packed, reliable, and clear-vision helmets come at a fairly reasonable price. They are a perfect option for both more demanding and hobby welders looking for the best protection for their money.
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How To Choose the Right Welding Helmet?
Once you understand the mistakes, it is much easier to avoid them and make the right choice. But if you are still unsure, here are some tips and guidelines to help you choose the correct helmet for your application.
Welding with a Right Helmet
Photo by @talovich3 (TikTok)
1. Always prioritize safety
Before even considering a specific helmet, make sure it meets ANSI Z87.1 or Z87+ standards. Safety is a top priority, and there is no room for compromise. A lack of information about safety standards should be an immediate turn-off for you.
Specifications for the YesWelder LYG-M800H-CP Auto-Darkening Welding Helmet
Source: https://www.youtube.com/watch?v=sZPJcbcDHSY
2. Look at weight and comfort
Your helmet should be a perfect fit. Make sure the helmet entirely covers your face and neck to avoid unnecessary burns. Look for a helmet with an adjustable headband. Having a multi-point adjustable headgear will help you distribute weight evenly.
Weight and fit are critical for a professional welder who spends full shifts under the hood. Helmets weighing around 20 oz are considered lightweight and perfect for everyday use. Hobby-use helmets are often a bit heavier, but you shouldnโt mind too much if you wonโt be using them for a prolonged time.
However, that doesnโt mean you should sacrifice comfort and weight. Our YesWelder LYG-M800HP weighs just over 20 oz and provides a good fit and comfort. But the best part is you wonโt have to break the bank to buy it.
YesWelder LYG-M800HP True Color View Auto-Darkening Welding Helmet
3. Fixed shade vs variable-shade helmets
Welding helmets today come in two primary categories:
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Fixed shade (passive welding helmets)
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Variable shade (auto-darkening welding helmets)
Fixed-shade welding helmets, as the name suggests, commonly have a fixed #10 shade. They are inexpensive, but they lack versatility. Helmets are always dark, even if you are not welding. So, you canโt see anything before you start an arc, meaning you have to lift it up and down between welding. Also, having a single shade means you wonโt be as protected in some applications, or you wonโt see your welds clearly in others.
Stick Welding Pipes Using a Fixed-Shade Helmet
Source: https://www.youtube.com/watch?v=FyM4wm0cdQM
Variable-shade helmets, also called auto-darkening helmets, are pretty adaptable. When the arc is off, they have a default shade of #3-#4, equivalent to sunglasses. You can cut or grind the pieces and adjust your position before welding without lifting the helmet. Once you start an arc, the sensors detect the intense light and darken the helmet to the chosen shade (#9-#13). Lower shades (#9) work well with low-amp processes such as TIG welding, while higher shades (#13) protect the eyes during high-amp applications (Stick welding).
The versatility of auto-darkening helmets makes them one of the most popular choices on the market today. The technology is also much cheaper, so very few people go with fixed shade.
MIG Welding Using the YesWelder Auto-Darkening Helmet
Source: https://www.youtube.com/watch?v=LITz7kLo-a4&t
4. Optical clarity and true color for better visibility
New helmets provide a nearly clear view of your weld puddle, allowing you to control it perfectly. But not all helmets offer a clear picture, so you should look at the optical clarity.
Optical clarity rating covers four categories:
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Optical quality (Distortion)
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Light diffusion (Blur/Sharpness)
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Luminous Transmittance (Consistency)
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Angle Dependence (Angular Consistency)
The lens quality is rated on a scale of 1 to 3 for each category, with 1 being the best and 3 the worst. An optical clarity of 1/1/1/1 means the helmet produces a clear, sharp image. However, a helmet with an optical clarity rating of 1/1/1/2 will do just fine, as long as you look directly at the weld. Some even suggest that 1/2/1/2 works for hobby and less-demanding welders.
In addition to clarity, we recommend looking for a helmet with a true-color feature. This advanced lens technology shows colors more realistically, reducing the traditional green tint. Combined with good optical clarity, true color will provide a clearer, more natural view of the weld area.
5. Viewing area size
The size of the viewing area is another fundamental factor to consider. Many welders today prefer welding helmets with a large viewing area. The larger the area is, the better you can look at the arc, the weld puddle, and the workpiece.
If you need better peripheral vision for non-shop work, look for a helmet with panoramic view (side windows), such as the YesWelder LYG-Q800D. These are ideal for field repairs, working at various angles, or seeing your surroundings more clearly to prevent hazards.ย
LYG-Q800D Panoramic View Auto Darkening Welding Helmet
Nonetheless, if you want to only focus on the weld, you can settle for a smaller viewing helmet, such as a YesWelder LYG-L600A. These are generally less expensive, and a single viewing pane might suffice if you are an occasional welder.
YesWelder LYG-L600A Auto-Darkening Welding Helmet
6. Switching speed for reduced fatigue
Switching speed, or reaction time, is the time it takes the auto-darkening function to turn on after the helmet detects light. Most welding helmets today are really fast, but there is a difference between professional-grade and hobby-grade helmets.
Professional-grade helmets often have a reaction time of 0.04 ms (1/25000 second) and faster. Entry-level helmets achieve switching speeds of approximately 0.1 ms (1/10000). The quicker the helmet switches, the less your eyes are exposed to light.
While these differences seem negligible, they can affect welders who spend extended periods welding. For example, professionals who work several hours may experience eye fatigue due to a low entry-level switching speed. Therefore, look at the switching speed based on your needs and expertise.
MIG Welding with an Auto-Darkening Welding Helmet
Source: https://www.youtube.com/watch?v=WMJC72LJOvI&t
7. Number and quality of sensors
The more sensors a welding helmet has, the easier it will detect the arc light. Professional-grade helmets have more sensors strategically placed to detect an arc when working out of position or in tight, cramped spaces.
When picking a welding helmet, the more, the better. Although more sensors raise the price of the helmet, always look for one with at least 3-4 sensors, to be safe in every situation.
Sensor quality also matters, as it determines the ability to distinguish between an arc and other light sources. The last thing you want is auto-darkening to trigger on a light bulb or the sun, or not turning at all when you strike an arc.
High-quality sensors also have low-amp arc detection. Helmets often rate the lowest amps that sensors can detect and trigger the auto-darkening function. Anyone working with TIG and micro-TIG welding should look for a helmet rated at 5 amps and below.
8. Fitting respirator, glasses, or cheating lens
If your job requires using respiratory protection, make sure it fits under your hood. Their design enables additional protection without sacrificing the primary role of a welding helmet.
An alternative is a PAPR weld helmet. The Powered Air Purifying Respirator (PAPR) System delivers fresh, clean air around their entire face and head. However, these are pricy and needed only if welding safety specifications and protocols require them.
If you have vision issues, make sure your helmet fits glasses or magnifying lenses. Due to proper fit, most helmets introduced support for so-called cheater lenses. These are more compact than your glasses and provide magnification to help reduce eye strain and make a puddle easier to see.
Install a Magnifying Lens in a Welding Helmet
Source: https://www.youtube.com/watch?v=hh1DnlRu2Dg
9. Power supply options
Helmets need power to trigger the auto-darkening function. In most cases, they use a battery to power their electronics. However, the advancement brought different power supply options, which can affect your helmet choice.
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Replaceable batteries: Once the batteries run out of power, replace them with new ones.
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Non-replaceable batteries: The cheapest option, but once they dry out, you can throw the helmet away.
Most welding helmets today add solar panels that extend the battery life. Solar panels capture arc light and charge the battery, extending the lifespan. Nonetheless, there are several types of power supplies that helmets use to power the auto-darkening function. The most common options are:
Common Power Types of Welding Helmets
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AAA batteries: Bulky and heavy batteries, but inexpensive.
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Lithium cell batteries: Lithium coin cell batteries offer the longest lifespan. They are compact, but pricier.
We recommend looking for a helmet with replaceable lithium batteries, ideally solar-assisted, for the longest lifespan.
Source: https://www.youtube.com/watch?v=nOu-yE33J_s
Final Thoughts
Welding helmets are an essential piece of Personal Protective Equipment (PPE). Buying the right one means long-term investing in safety and your eyesโ health. But many welders make mistakes.
Common mistakes include ignoring safety standards and choosing a helmet without checking the fit or comfort. In addition, some welders fail to properly tune their settings, ignore maintenance, or buy a helmet solely on price, which can be a mistake.
To make an informed choice, set your goals straight. Prioritize safety and choose a helmet with good optical clarity, a snug fit, a reasonable weight, and adequate protection and sensors for your everyday welding applications.
TIG Welding Diesel Fuel Tank
Source: https://www.youtube.com/watch?v=7ouFOtYjORo
๐งCommon Welding Helmet Mistakes & How to Choose the Right One FAQ
1. What is the best shade for welding?
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#9โ#10 โ Low-amp welding (e.g., TIG)
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#11โ#12 โ Medium amperage
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#13 โ High-amp welding (e.g., Stick)
If the shade is too dark, you wonโt see the weld clearly. If itโs too light, you risk eye damage.
2. How many sensors do I need?
Look for a welding helmet with at least 3โ4 sensors for reliable arc detection, especially when working in tight spaces or out of position. More sensors can improve performance, but sensor quality is equally important to avoid false triggering from other light sources and to ensure stable low-amp arc detection.
3. What is the best helmet for beginners?
Beginners should choose a reliable auto-darkening helmet with good optical clarity and protection rather than focusing only on price. Budget-friendly, feature-balanced helmets from YesWelder are a good starting point for most beginners.
4. What viewing area size should I choose?
Choose a viewing area based on your work needs. Larger viewing areas provide better visibility of the arc, weld puddle, and surroundings, and panoramic designs like YesWelder LYG-Q800D are suitable for field work. If you weld occasionally or want a more affordable option, a smaller viewing area, such as YesWelder LYG-L600A is usually sufficient.
๐ย You may be interested in the following:
- 10 Most Common Welding Mistakes
- How To Choose The Right Welding Types
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What Makes a Welder Truly User-friendly?
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