Welding Helmets & Lens Shades
A welding arc gives off intense visible light, ultraviolet and infrared radiation that can burn your eyes and skin in seconds. A welding helmet with the right shade lens protects your eyes and face, but only if it’s the right shade, in good shape, and worn with safety glasses underneath.
- Welders
- Construction
- General Industry
Passive vs. auto-darkening
| Type | How it works | Pros | Cons |
|---|---|---|---|
| Passive | A fixed dark lens, usually shade 10 | Cheap, simple, no batteries | You must flip it down before striking; hard to see the joint |
| Auto-darkening | Sensors darken the lens in a fraction of a second when the arc starts | Keep the helmet down; better accuracy; adjustable shade | Costs more; batteries and sensors must work |
Good auto-darkening lenses still block UV and IR even when light, and they have settings for shade, sensitivity and delay. Many have a grind mode for grinding with the helmet on.
Choosing the shade number
Higher numbers are darker. Start at the minimum for your process and current, then go darker until you can see the weld puddle comfortably without straining. Common minimums:
| Process | Minimum shade |
|---|---|
| Stick (SMAW), electrodes under 3/32 inch (under 60 amps) | 7 |
| Stick, electrodes 3/32–5/32 inch | 8 |
| Stick, electrodes 5/32–1/4 inch | 10 |
| MIG and flux-core (GMAW/FCAW), 60–500 amps | 10 |
| TIG (GTAW), 50–150 amps | 8 |
| Air carbon arc cutting, light | 10 |
| Plasma arc cutting, light (under 300 amps) | 8 |
| Torch brazing | 3 |
| Oxyfuel cutting, light to heavy | 3 to 5 |
See the full table in OSHA’s eye protection standard and Eye & Face Protection.
Markings and fit
- The helmet and lens should be marked to ANSI Z87.1. Welding filters show a W and the shade number.
- Adjust the headgear so the helmet stays put when you nod, and the lens sits square in front of your eyes.
- A helmet is not impact protection for your eyes when it’s flipped up. Always wear Z87+ safety glasses under it for chipping slag and grinding.
Inspect before you weld
- Shell has no cracks, holes or burn-throughs that let light in
- Outer cover lens is clean and not pitted with spatter; replace it when it is
- Auto-darkening lens darkens when tested (strike a lighter or use the test button)
- Battery is charged and sensors are clean and uncovered
- Shade, sensitivity and delay are set for today’s process
- Headgear is tight and not cracked
Arc flash burns bystanders too. “Arc eye” or welder’s flash can hit anyone who looks at the arc, and it often hurts hours later. Use welding screens or curtains, and warn people before you strike an arc.
Fumes are a separate hazard
A helmet doesn’t protect your lungs. Use local exhaust ventilation, keep your head out of the plume, and wear a respirator when required. Welding helmets with built-in PAPRs combine eye, face and lung protection. See PAPRs and Hexavalent Chromium.
Standards & references
- 29 CFR 1926.102: Eye and face protection (construction), including filter lens shades
- 29 CFR 1910.252: Welding, cutting and brazing, general requirements
- OSHA: Welding, cutting and brazing
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