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A welding helmet is a type of personal protective equipment used in performing certain types of welding to protect the eyes, face, and neck from flash burn, sparks, infrared and ultraviolet light, and intense heat. The modern welding helmet used today was first introduced in 1937 by Willson Products.[1]
Welding helmets are most commonly used in arc welding processes such as shielded metal arc welding, gas tungsten arc welding, and gas metal arc welding. They are necessary to prevent arc eye, a painful condition where the cornea is inflamed. Welding helmets can also prevent retina burns, which can lead to a loss of vision. Both conditions are caused by unprotected exposure to the highly concentrated infrared and ultraviolet rays emitted by the welding arc.[2] Ultraviolet emissions from the welding arc can also damage uncovered skin, causing a sunburn-like condition in a relatively short period of welding. In addition to the radiation, gases or splashes can also be a hazard to the skin and the eyes.[3]
Most welding helmets include a window (visor) covered with a filter called a lens shade, through which the welder can see to work. The window may be made of tinted glass, tinted plastic, or a variable-density filter made from a pair of polarized lenses. Different lens shades are needed for different welding processes. For example, metal inert gas (MIG) and tungsten inert gas (TIG) welding are low-intensity processes, so a lighter lens shade will be preferred.
United States OSHA requirements for welding helmets are derived from standards like ANSI Z49.1, Safety in Welding and Cutting, section 7 (Protection of Personnel)[4] and ANSI Z89.1 (Safety Requirements for Industrial Head Protection).[5]
The shade of lens that is suitable depends on the current rating of the weld. In the United States, OSHA recommends DIN shade numbers as shown in the following table:
| Weld Current (Amperes) |
Shade Number |
|---|---|
| 50–60 | 10 |
| 60–160 | 11 |
| 160–200 | 12 |
| 200–240 | 13 |
| > 240 | 14 |
The 1967 edition of ANSI Z49.1.7.2.2.10 specifies that "all filter lenses and plates shall meet the test for transmission of radiant energy prescribed in paragraph 6.3.4.6 of the Safety Code for Head, Eye and Respiratory Protection, USA Standard Z2.1-1959".[4]
As of 2023, OSHA's website provides standards for minimum protective shades under standard 1910.133 (Eye and face protection), section (a)(5), and says: "As a rule of thumb, start with a shade that is too dark to see the weld zone. Then go to a lighter shade which gives sufficient view of the weld zone without going below the minimum. In oxyfuel gas welding or cutting where the torch produces a high yellow light, it is desirable to use a filter lens that absorbs the yellow or sodium line in the visible light of the (spectrum) operation."[6]
- ^ "One Piece Helmet Cut To Protect The Welder Popular Mechanics, August 1937 -- bottom-left of page 217
- ^ Elvex Safety Products How Light Affects the Eye
- ^ "Testbericht zur Automatik-Schweißmaske Speedglas 100 von 3M". Testberichte für Testsieger (in German). 2017-01-12. Retrieved 2017-01-29.[permanent dead link]
- ^ a b "ANSI Z49.1 Safety in Welding and Cutting" (3 ed.). American National Standards Institute. 1967.
- ^ "ANSI Z89.1 Safety Requirements for Industrial Head Protection" (3 ed.). American National Standards Institute. 1969. p. 14.
- ^ "1910.133 - Eye and face protection". United States Department of Labor, Occupational Safety and Health Administration.