Welding Helmet Lens Shade Chart With Calculator

When using a welding helmet, the shade number of its lens is a critical choice. It needs to align with the ARC’S AMPERAGE for optimal protection, as different processes call for different glass shades.

Using a lens that isn’t dark enough won’t provide sufficient protection. Conversely, a glass with an unnecessarily high DIN number can reduce visibility and may even fail to activate when needed.

To help you understand the shade requirements for various welding techniques and amperages, I’ve put together a comprehensive guide with a chart. Additionally, I’ve developed a Welding Lens Shade Calculator based on OSHA, ANSI, and AWS recommendations. This tool is compatible with different types of helmets and should give you a clear idea of what you need.

Welding Helmet Shade CALCULATOR

When apprentices join my workshop, they often feel confused about the lens shade required for the task at hand. Eventually, Oliver Freling, my workshop manager, and I decided to create a chart listing all the shade recommendations and hang it up on the board to help them out. And hey, don’t worry, I’m sharing it here too!

Shade CHART For Welding Lenses

The Occupational Health and Safety Administration (OSHA) sets minimum lens shade requirements for different arc current amperage. So, our top priority is to ensure everyone at our workshop uses the correct shade.

ANSI and AWS recommendations are advisable for those who prefer to EXCEED the minimum necessity with more safety and comfort. Their minimum shade numbers for welding helmets are typically 1 to 3 shades darker than the OSHA requirements as shown in the following chart.

The above infographic should already give you an idea of the different shade requirements, but let me elaborate on the chart in a simplified way.

Shielded Metal Arc Welding (SMAW)

The amperage can range from less than 60 to more than 550 for SMAW. According to OSHA guidelines, you should wear a shade #7 lens when welding at below 60 amps. As the amperage goes up, so does the required shade number, up to #11.

Flux Core Arc Welding (FCAW)

The amperage range for FCAW is very similar to that of SMAW, except that it’s capped at 500 amps. A shade #7 lens will suffice when welding at less than 60 amps, but OSHA guidelines require you to use at least a shade #10 lens for any higher amperage – be it 150 or 500.

Gas Metal Arc Welding (GMAW) or MIG

The amperage range and glass shade requirements for MIG welding are exactly the same as those for FCAW. The amps range from less than 60 to 500, while the required lens shades are #7 and #10 for below and above 60 amps, respectively.

Gas Tungsten Arc Welding (GTAW) or TIG

The amperage can vary from below 50 to as high as 550 amps for TIG welding. Likewise, the required shade range, as per OSHA guidelines, ranges from #8 to #10. The flash isn’t as bright as other welding methods, which is why a shade #8 would suffice up to 150 amps. You can get helmets specifically rated for TIG to suit the low-brightness arc.

Plasma Arc Welding (PAW)

Plasma arc welding has one of the widest possible variations in amperage, ranging from less than 20A to 800A. You only need a shade #6 lens when welding at below 20A, but a shade #8 is needed for anything between 20 and 100 amps. Plasma arc welding at 100A to 400A requires a #10 glass, whereas you’d need a mask with shade #11 if the amps go any higher.

Carbon Arc Welding (CAW)

This welding technique generates one of the brightest arcs, requiring welders to wear a shade #14 helmet at the very least. This is the only method for which OSHA recommends shade #14, which is typically the darkest lens you can get in a hood.

Air Carbon Arc Cutting (CAC-A)

Moving on from welding, air carbon arc cutting produces high amperage arcs that can go up to 1000A. You need a shade #10 lens if it’s less than 500A and a shade #11 if it is 500A to 1000A.

Plasma Arc Cutting (PAC)

The amperage for plasma arc cutting can range from below 300A to as high as 800A. Depending on the amps, the required lens shade varies from #8 to #10.

Torch Soldering

Unlike any type of arc welding, the light generated while torch soldering isn’t very intense. A shade #2 glass should be enough to protect your eyes. For context, auto-darkening helmets usually remain at #3 when you aren’t welding to grant adequate visibility – which means a shade #2 lens only slightly darkens the surroundings.

Torch Brazing

Torch brazing generates a slightly brighter light compared to soldering, requiring you to use a shade #3 or #4 welding lens.

I’d like to reiterate an important detail: simply following the minimum lens share requirements isn’t enough—you’d have to make sure that your helmet’s shade range isn’t TOO DARK.

This presents a tricky problem – back when I tried TIG welding while wearing an AD hood for the first time, I was in for a nasty surprise…the glass didn’t darken!

This is because standard auto-darkening helmets have a DIN range of #9 to #13 or #14. Such a welding mask would darken the lens only when the arc generates a flash bright enough to require shade #9 darkening. The 75A TIG arc simply wasn’t bright enough to trigger the auto-darkening filter.

This was a long time ago – I have since learned to use auto-darkening welding helmets with an additional range of #5 to #9 for TIG welding when going for variable shade. Fixed-shade AD hoods or passive lenses work too – just make sure the darkness is appropriate.

How To Choose A Lens Shade Ideal For Your Welding Mask?

In addition to selecting the right helmet for the job, you’ll also need to adjust the glass to the appropriate darkness if it’s a variable shade with auto-darkening features. While this might seem a bit tricky, choosing the ideal lens shade for your fabrication project is actually quite simple.

First, you need to select the welding process. This can include Shielded Metal Arc Welding (SMAW), Flux Cored Arc Welding (FCAW), Gas Metal Arc Welding (GMAW) or Metal Inert Gas Welding (MIG), Gas Tungsten Arc Welding (GTAW) or Tungsten Inert Gas (TIG) Welding, Plasma Arc Welding (PAW), and others.

Next, choose the range of arc current in amperes, which varies for different welding methods. For example, TIG may require electricity ranging from less than 50A to 500A, while PAW may need power ranging from less than 20A to 800A.

Based on the type of process and arc current, you can find the lens shade range of your welding mask from the calculator as well as the chart, according to OSHA, ANSI Z87.1, and AWS guidelines.

Factors such as material thickness, welding position, and eye sensitivity also play vital roles in determining the perfect shade. For example, overhead welding may require more darkness to protect against glare.

Lens Shade Trends: Current Status In 2024

Welding standards are constantly evolving to meet new findings and changing standards. As of 2024, modern welding helmets offer variable shade and auto-darkening options for adjusting darkness based on the task, ranging from #3 to #13.

They feature sensitivity and delay adjustments for customizing lens reaction times. And guess what? Optical clarity has improved with better coatings and optics, reducing eye strain. But that’s not all! You can now find welding hoods with variable shade glasses, compatible with MIG, TIG, PAW, SMAW, and various cutting processes.

I personally prefer to follow the ANSI Z87.1 standards and AWS recommendations because not only are they safer, but my helmet would still be good enough in case OSHA raised a requirement by a shade or two.

OSHA compliance isn’t the only reason to pick appropriate lens shades while welding. It’s a matter of safety for your eyes – something you wouldn’t want to compromise at any cost. Always make sure to use the necessary eye protection while working with any welding or arc-cutting equipment.