Auto Darkening Filter (ADF) Vs Passive Welding Helmets

Exploring the Differences between Auto Darkening Filter (ADF) and Passive Welding Helmets
 

The welding process involves the joining of metals by the application of high heat. During this process, welders are exposed to various hazards, including UV/IR radiation. Personal protective equipment such as welding helmets offers protection from arc flash, sparks, flying objects, heat, welding fumes, harmful UV/infrared light, and other environmental hazards associated with welding, grinding, and cutting. 

Based on the type of filter lens, welding helmets can be categorized as:

1. Passive Welding Helmet
2. Auto Darkening Welding Helmet

The present blog provides a deeper insight into these welding helmets and helps you understand which works best for your welding application. 

Passive Welding Helmets

Passive helmets were the only choice that the welders had for several decades. These helmets feature handheld shields or wearable on the forehead. With technological advancement, auto-darkening welding helmets have emerged as the preferred choice for welders. The modern welding helmets are designed with advanced features to adjust the shade lens automatically in response to the welding arc. They offer enhanced comfort, higher optical clarity, increased flexibility, and superior protection to meet the most demanding welding applications. 

Despite the advanced automatic features and components of auto-darkening helmets, many welders opt for passive helmets. The primary reasons for this include its affordability and availability of dark lenses for easy replacement. However, passive helmets have their own set of drawbacks. Unlike their auto-darkening counterparts, passive helmets do not adjust lens shade in response to the welding arc. As a result, welders need to remove the helmet to inspect the weld, exposing them to harmful UV/IR radiation. 

Their significant disadvantage is taking it off to check out the weld during the process and no UV/ IR protection. The puddle clarity and flash prevention are among a few positives. The helmet's sturdiness, positioning, and flipping can be challenging.   

Pros and Cons of Passive Helmets:

S.No	Pros	Cons
1	Affordable	Requires manual positioning
2	Lightweight	The filter lens needs to be changed accordingly with the change in welding current.
3	Availability of replaceable dark lenses	Limited adjustments with no advanced features
4	Operates without any power source	Not user-friendly for beginner welders

ADF (Auto-Darkening) Welding Helmets

Auto-darkening helmets have revolutionized the welding industry, offering superior safety and efficiency. Unlike passive welding helmets, which need to be manually removed to inspect the weld, auto-darkening welding helmets are designed with advanced auto-darkening filters (ADF) to adjust the shade lens automatically in response to the welding arc. The welders can weld continuously with the helmet on. Further, auto-darkening helmets are designed with advanced features, including sensitivity control, grind modes, adjustable shade ranges, and arc sensors. 

The auto-darkening filter comprises a specialised liquid crystal display that activates instantly as the arc sensors detect any change of light in the surroundings. The sensors in ADF helmets detect radiations from sunlight and welding arcs. Auto-darkening welding helmets mostly operate on batteries. The solar panels on the front screen energise the liquid crystals during welding to help save battery power. 

Pros and Cons of ADFs:

S. no	Pros	Cons
1	Auto-darkening filter gets activated when the sensor detects light	Repair, spare parts, and maintenance can be expensive
2	Features adjustable shade range from 9-13	Battery operated, which needs replacement
3	Superior optical clarity	Expensive than Passive helmet
4	Options available to fit with respiratory system for lean air to welder.
5	Provides IR protection even when ADF is not on

Passive Welding Helmet vs Auto-darkening Welding Helmet

Factor	Passive	ADFs
Welding Process	MMA/ MIG/ TIG/ SAW, need to replace Filter Lens	MMA/ MIG/ TIG/ SAW,, based on Shade selections available
Shade Selection	Fixed	Variable
Grinding Mode	NA	Available, based on model
Advanced Feature	NA	Sensitivity and Delay Setting
Visibility	Poor welding vision, good puddle control	High optical clarity before and during welding
Arc Sensors	NA	Available, 2-4 arc sensors
Maintenance/Replacement Lens	Affordable, easy to repair and replace	Expensive to repair and replace
Price	Less expensive with minimal features	Expensive due to advanced features

When choosing the right welding helmet, it Is essential to consider the pros and cons of each type based on your welding application. Passive welding helmets are lightweight, easily replaceable, operate without batteries, and have limited features, making them inexpensive. Auto-darkening welding helmets offer advanced features like superior optical experience with productivity-enhancing benefits, making them expensive. Superior optics can help welders keep the weld puddle centered in the joint, keep the electrode on the edge of the puddle, and position the cutting torch accurately, reducing eye fatigue. Selecting the right welding helmet ensures the welders have a safe and efficient welding experience with increased productivity.