Choose a lens with an AAA battery for economical replacement cost and availability everywhere. Choose a lithium battery model for extended battery life. However, lithium batteries have higher replacement costs and are slightly more limited in availability. Typical AAA battery life is approximately 2,000 hr for MIG welding.

Adjustable Sensitivity and Delay Controls

Both intermediate and professional level auto-darkening helmets usually provide the ability to adjust how much brightness will trigger the lens to darken.

Sensitivity control is useful when welding at low amperages — especially with a process such as TIG, when the arc isn't as bright as it is with other welding processes.

A delay control is another useful feature.

This control enables you to set how long the lens stays dark after the welding arc stops.

When tack welding on a large project, a short delay helps to get the job done faster as you reposition for the next weld. A longer delay time is helpful when welding at very high amperages to prevent you from looking at the weld zone after the arc extinguishes.

Depending on the manufacturer and price, these features often are controlled by toggle switches for high/low sensitivity and fast/slow delay. Professional level helmets typically will use infinite range dials to deliver greater adjustment capability. Entry-level auto-darkening helmets typically do not have either of these features.

Helmet Weight

A lighter weight helmet minimizes strain on the user's neck and reduces fatigue while increasing comfort.

You will notice a big difference between a helmet that weighs 1 lb versus one that weighs 2 lb.

While 1 lb might not seem like much for a few short welds, it can become a great weight when working on an all-day project.

Think of the old trick of holding a book out at arm's length. It's easy for the first few seconds, but it seems to weigh a ton after a minute or two.

The same goes for a heavy helmet vs. a lighter option: sooner or later, greater weight will cause discomfort.

National Safety Standards

The most recent safety standard for welding helmets is ANSI Z87.1 – 2003. This standard requires helmet and auto-darkening lens manufacturers to validate their advertised specifications such as switching speeds, darkness shade settings, and other specs, through independent laboratory tests to advertise compliance.

These rigorous tests require the helmet and lens to survive high velocity impact tests from flying objects, provide 100 percent ultraviolet and infrared filtering regardless of shade setting, and meet advertised switching speeds and darkness shades in extreme temperatures.

The auto-darkening lens must engage and perform at temperatures as low as 23 degrees F and as high as 131 degrees F to ensure consistent protection. If you live in Texas or Minnesota, that's real world welding.

Buyer Beware

Not all helmets on the market meet the current safety standard.

Prior to 2003, the ANSI standard dated back to 1989.

At that time, there were no temperature test guidelines required.

Even today, nothing prevents a manufacturer from selling helmets made under the old standard.

The switching speed and shade level can be much slower than advertised, exposing your eyes to the welding arc.

What should you look for? Be sure the helmet packaging and product advertises either “ANSI Z87.1 – 2003” or “Z87+.” That means the helmet has the latest approval of the American National Standards Institute and Society of Safety Engineers. Just because the product says “ANSI Approved” does not mean it passed the 2003 standard.

For more information on selecting the right helmet suited for light to moderate applications, visit http://www.hobartwelders.com/weldit/safety_equip/.