4 Best Auto Darkening Welding Lens for Welders’ Safety
Welders use a special helmet for their safety, and it contains a lens that protects the eyes from harmful radiation produced during the welding process. Whether you are using a chopped welding hood, pipeline welding hood, pancake welding hood, or any other, all of them need a lens.
Nowadays, most welding helmets contain an auto darkening lens. It is an incredible invention that gets dark and clear automatically and keeps the welder safe from harmful radiation.
Beginners usually have tons of questions related to this lens before they buy one for their use. Therefore, in this article, we will tell you everything about an auto darkening lens. We will explain what it is and how it works. We will also share some of the best auto darkening lenses on the market to make your selection easier.
What is an Auto Darkening Lens in Welding?
An auto darkening lens is a special lens for welding helmets. In normal conditions, the lens looks clear. You can easily see directly through it. But when you start the torch, the lens senses the light and turns dark. It blocks harmful radiation quickly.
Initially, simple or passive lenses that remain dark all the time were used in welding helmets, and still, many welders use and prefer them over auto darkening welding lenses. Experienced welders know how to get the job done using a passive lens.
However, there are various issues with the passive lenses that many welders face, especially beginners. Firstly, due to the dark shade of the lens, they can’t see the object clearly. They do not have a clear vision of the spot they need to weld. Moreover, they hardly see the tip of the welding electrode. Due to these problems, it becomes difficult to weld the object.
An auto darkening lens is an excellent choice. These lenses are clear in normal conditions and get dark when the torch starts. The auto-darkening effect helps welders’ weld with perfection in all conditions, whether it is dark or under the hot sun. They make the job of beginners easier, and some experts also use them for their welding jobs. It completely depends on the preference of the welder.
Main Components of an Auto Darkening Welding Lens
There are three important parts in an auto darkening welding lens and all of them work together to protect the eyes of the welder from ultraviolet and infrared radiations.
The three parts are,
- UV/IR Filter
- Polarization Filter
- Liquid Crystal Cell Filter (LC Filter)
The UV/IR filter is responsible for creating hindrances in the path of UV and IR radiations. It is the first barrier exposed to the welding area. The IR rays are completely absorbed, and the layer does not allow them to pass through. Most of the IR rays are blocked; however, 0.1-0.05% of rays are still able to pass, which are blocked by the other layers.
The next layer of filters is Polarization Filters. Along with the UV/IR filter, they absorb 99.9% of the UV radiation. These are arranged in different directions and orientations and placed along with Liquid Crystal Cell Filter (LC Filter).
After the UV/IR filter, there is a Polarization Filter followed by an LC filter. Then, there is a Polarization Filter again followed by the LC Filter. These two types of layers are sandwiched to block the radiation. The first polarization filter is at 90 degrees and the others are perpendicular to it, which means they are at 0 degrees.
The polarization filters, when arranged at 90 degrees, block the light coming from outside. It means the lens becomes darker and your eyes are not affected by the bright light. When these are arranged at 0 degrees from each other, you can see directly through them and there is no blockage of light. So, the shade of the lens can be changed through the polarization filters. It does not block everything; however, it protects from the most harmful radiation.
The last layer is the Liquid Crystal Cell Filter (LC Filter), which plays the most important role. These contain special liquid crystals that have the ability to deviate light. When they are arranged in a flat plane, any radiation or light is twisted by 90 degrees. When they are triggered by an electric current, they bend the light according to the requirement.
They have the capability to control the darkness of the lens because they can be controlled by electric current. It gets dark automatically when the torch starts. There is a sensor on the auto darkening lens that senses the intensity of the light. It gives the current to the LC Filter to arrange the crystals as required. The current is produced by a simple cell or solar cell. With low current, the crystals of the FC Filter are aligned.
How do Auto Darkening Welding Lens Work?
The working of an auto darkening welding lens is a bit complicated due to high-tech involvement. However, you should know how they work to figure out the issues, understand how safe it is, and know when you need to replace the lens.
The IR radiations are filtered by the first UV/IR filter. It protects the inner layers from heat by blocking the IR radiations. We have discussed that most of the IR radiations are blocked, and the UV radiations are blocked with the combined working of the UR/IR filter and the polarization filter.
When the torch is off, the light passes through the first polarization filter. The lens is in its dark state around the shade of 5-6. The FC Filter is also off as the sensors do not sense any light and produce current. It twists the light and changes its direction to give a clear and bright view. So, at this stage, you see clearly through the lens without the darkening effect.
When you start the torch, the polarization filter again blocks the light by changing its direction. This time, the FC Filter turns on through the current received after sensing the light. The crystal cells are arranged according to the intensity of the light. At this stage, the lens becomes dark to protect the eyes.
In simple words, the LC filters act automatically according to the intensity of the light. When the torch is off, it is bright, and when the torch is on, it becomes dark and protects your eyes.
Is the Auto Darkening Welding Lens Safe?
The auto darkening welding lens is completely safe. It contains various layers that protect your eyes. The UV/IR layer blocks the IR radiations. It keeps the heat away from the eyes and blocks the radiation. Then the UV rays are blocked by the UV/IR and polarization filters. Till this stage the lens is dark, and there is no involvement of the cell or electric current. So, even if the FC filter does not work, you still have some protection from harmful radiation.
Now, the FC Filter plays its role. It works at 1/30,000 of a second, which is quite fast. It further blocks the light and makes the lens darker. However, it needs an electric current to operate. So, you should carry the spare batteries in your welding skid. If there is a solar cell, it works through the sunlight. Make sure they are charged.
Thus, an auto darkening welding lens keeps your eyes safe from harmful radiation and allows you to work without any hassle. It is convenient for beginners and most experts also prefer it. We have explained the working of lenses in the previous section to give you a complete idea of how safe the lens is.
How Long Do Auto Darkening Welding Lenses Last?
The auto darkening welding lens lasts for about 3-10 years, depending on the quality. The best part is that you can change the lens in pancake and chopped welding hoods without any hassle. They are easily available on the market, and we will also share some of the best lenses for you to replace whenever needed.
But keep in mind that the lithium-ion batteries work for about several months to 1 year. You need to replace them after that. If they are powered by solar, charge them whenever needed.
How to Select an Auto Darkening Lens
If you need to buy an auto darkening welding lens, there are a few factors that are a must to consider. We are going to explain these factors to make your choice easier.
Quality
The first thing is the quality of the lens you are buying. An auto darkening lens is a safety feature of your welding helmet, so you can’t compromise on the quality. Always go with reliable manufacturers in the field. Even if you have to spend more than cheap brands, go for it.
Shade
You will notice the shade grading on every auto darkening welding lens. Its value can go up to 14. Beginners usually get confused about which shade is right for them.
It completely depends on the type of welding you do. If the welding produces very intense and bright light, you will have to go with the highest shade. For each welding process, the requirement of lens shade is predicted through the art current and welding process.
For instance, if the current in Shielded Metal Arc Welding (SMAW) goes around 250-550 amperes, the minimum lens shade for protection is 11, while the suggested shade is 14. If you do not go up to these high currents, you can get a lighter shade. For 160-250 amperes, shade 10 is the minimum requirement, and shade 12 is suggested.
Thus, you have to select the welding you do and the current ratings. You can check various safety standards before selecting the shade. OSHA recommends the following shades for the currents.
Some auto darkening welding lenses also offer variable shades. Their shades, sensitivity, delay, and other things can be adjusted. They usually have different knobs on the lens that are used to get the desired results. However, these lenses are costly.
Solar Powered or Replaceable Batteries
The auto darkening lenses can be solar-powered or battery-powered.
The solar-powered lenses have a solar rechargeable cell. It works perfectly well under the sun, but you can also charge it to use in the dark.
The second option requires a replaceable battery. It lasts for several months to a year.
Both are good options, and you can choose according to your convenience.
Lens Switching Speed
The switching speed of the lens indicates the time required to switch from dark to light and vice versa. When you turn off the torch, there is a minimal delay in the lens to turn bright again and come to its normal condition, and this delay is called switching speed or switching time.
It is an important factor to consider. If the switching speed is high, you will experience eye fatigue and other issues. The lens should switch faster to offer you enough comfort so that you can work without any hassle. The faster the switching speed, the better it is, and it will increase the cost of the lens.
The switching speed ranges from 1/3,600 sec to 1/20,000 sec. Cheap lenses have a speed of around 1/3,600 sec, which is not good. Then, we have professional lenses that have a switching speed of around 1/10,000 sec to 1/20,000 sec. Make sure the switching speed is advertised properly and the manufacturer is reliable.
Some manufacturers also mention the switching speed in milliseconds. For that, you can convert the value into fractions to get a better idea.
Warranty
Check the warrant of the welding lens before purchasing. Reliable manufacturers offer a warranty of 1-2 years.
4 Best Auto Darkening Lens for Welders
We have picked some of the best auto darkening welding lenses you can use in your welding helmet. We are going to list them here and explain their features, pros & cons, and other specifications.
1) LINCOLN ELECTRIC Variable Shade Auto-Darkening Welding Lens
This is an incredible auto darkening welding lens from a reliable company. It allows the welder to adjust multiple settings and set the lens according to the requirement.
Firstly, the shade of the lens can be changed. It offers 8-13 shades that can be selected through the knob. It can be used for a wide range of welding processes, including low and high art currents. Along with that, the welder can adjust the delay settings to personalize switching. Therefore, you can adjust it according to your comfort. Last but not least is the sensitivity adjustment which can be customized according to the welder.
The lens is powered by a solar cell and replaceable batteries. With that being said, it works on solar energy and switches to the battery mode when needed. It enhances the life of the batteries. Plus, there is a battery indicator to know when it is time for replacement.
You get a clear view of the object without any strain on the eyes. It gives a true color view by eliminating the situation. It is possible to use it in both the dark and bright conditions.
The size of the lens is 2” x 4”, which is an ideal option for pancake and pipeline welding hoods. For professionals, it is an ideal option because of the variable settings and optimal quality. It is a bit costly but worth every penny. Moreover, there is a 2-year warranty for the product, so you can buy it without any worries.
2) ArcOne Auto Darkening Welding Lens Shade Variants 8, 9, 10, 11, and 12
ArcOne is also a great choice when it comes to auto darkening welding lenses. Their lenses are incredible and offer clear vision and long service.
The company offers different variants of shade, including 8, 9, 10, 11, and 12. You can easily choose the shade you are looking for. The lenses are suitable for multiple welding jobs. 10 and 11 shades are the most commonly bought shades. It gives you a clear view of the working area. Plus, there are two independent sensors to sense the welding torch and its intensity.
The switching speed of the lens is 0.5 milliseconds, which is 1/2000 second. It can be better, but it is also equipped with a dark-to-light delay of 0.2 seconds to reduce eye fatigue and exposure to light.
It is an affordable solar-powered auto darkening welding lens that welders can use. It comes with a 3-year warranty, which indicates its durability and long service.
3) Lincoln Electric Auto Darkening Lens Shade Variants 9, 10, 11
This is another auto darkening welding lens from Lincoln Electric. It is a fixed shade welding lens, which has multiple variants of shades, including 9, 10, and 11.
It is a solar-powered lens with an incredible switching speed of 1/10,000. It is excellent for professional use due to its durability and premium lens technology. If you are looking for a fixed shade lens, it could be an excellent choice.
The lens offers perfect vision and optical clarity. You will not experience any blurriness and distortion. The most important thing is the high-temperature housing, which keeps the lens safe from heat and increases its life.
The manufacturer offers a 2-year warranty for the lens.
4) Miller Auto Darkening Welding Lens Shade 10
Miller does not need an introduction. Their products can be bought without any worries. The welding lenses are considered the best on the market because of their performance, true specifications, and durability.
It is a shade 10 auto darkening welding lens powered by solar cells. It is according to ANSI/CSA standards, which ensures your safety.
The size of the lens is 2 x 4 inches, and it is suitable for Miller welding helmets. However, it can be used in other pancake and pipeline welding hoods that are compatible with this size.
It is a great replacement lens for welding professionals. Shade 10 is suitable for various welding processes. If you try it once, you will definitely buy it again and again.
This lens also comes with a 2-year warranty.
Final Words
An auto darkening welding lens undoubtedly makes welding easier. It allows welders to see clearly and protect their eyes from intense light and harmful radiation. We have explained its detailed phenomena to give you a complete idea of how it protects your eyes and helps you weld with perfection. We have shared some factors to consider while buying an auto darkening welding lens. For your ease, we have also hand-picked some of the best lenses on the market to make your selection easier.
Get a reliable and excellent auto darkening welding lens today and give comfort to your eyes.
