Welding produces four invisible hazards that can permanently damage your eyes: ultraviolet radiation, infrared radiation, intense visible light, and molten metal spatter. The wrong eye protection — or no protection — causes arc eye (photokeratitis) within hours and cumulative retinal damage over years.
Choosing the right protection means understanding two things: the shade number required for your welding process, and which Australian standard actually governs the product. This guide covers both, along with filter types, goggle vs helmet selection, and what to look for in an auto-darkening helmet.
Two Standards, Two Jobs: AS/NZS 1337.1 vs AS/NZS 1338.1
Most Australian welders know they need "AS/NZS 1337" compliant eye protection, but there are actually two separate standards at work:
| Standard | What It Governs | Applies To |
|---|---|---|
| AS/NZS 1337.1:2010 | Eye protector frame and lens construction — impact resistance, optical quality, coverage, comfort and marking requirements | All occupational eye protectors including welding helmets and goggles |
| AS/NZS 1338.1:2012 | Welding filter lens performance — shade numbers, UV transmission limits, infrared transmission limits, and luminous transmittance | Welding filter lenses and screens only |
A compliant welding helmet must satisfy both: the physical construction standard (1337.1) and the filter performance standard (1338.1). When a product is marked "AS/NZS 1337.1" only, that tells you the frame and optics are certified — it does not confirm the filter shade is correctly rated. Look for both standard references on the marking or product documentation.
Welding Shade Number Guide by Process
Shade numbers run from 1.7 (almost clear) to 16 (extremely dark). Higher numbers block more ultraviolet and infrared radiation. The correct shade depends on the welding process and the amperage — higher amperages produce more intense arcs that require darker filters.
The table below is based on AS/NZS 1338.1:2012 recommendations. The minimum shade is the lowest you should use; the recommended shade accounts for practical comfort over long periods.
| Process | Operating Range | Min. Shade (AS/NZS 1338.1) | Recommended Shade |
|---|---|---|---|
| Oxy-acetylene welding | Light (small tip) | 4 | 4–5 |
| Medium | 5 | 5–6 | |
| Heavy (large tip) | 6 | 6–8 | |
| Oxy-acetylene cutting | Light (<25mm) | 3 | 3–4 |
| Heavy (>25mm) | 4 | 4–5 | |
| Stick / SMAW | <60 A | 7 | 10 |
| 60–160 A | 10 | 11 | |
| 160–250 A | 11 | 12 | |
| 250–550 A | 13 | 14 | |
| MIG / GMAW / FCAW | 60–160 A | 10 | 11 |
| 160–250 A | 11 | 12 | |
| 250–500 A | 13 | 14 | |
| TIG / GTAW | <50 A | 8 | 10 |
| 50–150 A | 10 | 12 | |
| 150–500 A | 12 | 14 | |
| Plasma cutting | <20 A | 6 | 8 |
| 20–40 A | 8 | 9 | |
| 40–60 A | 9 | 12 | |
| Air carbon arc cutting | All amperages | 10 | 12–14 |
| Brazing / silver soldering | All | 3 | 3–4 |
| Grinding (post-weld) | All | Clear impact lens (AS/NZS 1337.1 — not a welding filter) | |
Important: Grinding does not require a welding filter shade — it requires an impact-rated clear lens. Using a dark welding filter while grinding reduces visibility without providing any benefit, and obscures sparks that could signal a problem. Keep a separate pair of impact safety glasses for grinding.
Filter Types: Passive Lens vs Auto-Darkening
Passive (fixed-shade) filters
A passive filter is a fixed-density glass or polycarbonate lens set to a specific shade number. They are simple, reliable, and have no batteries or electronics to fail. The trade-off is that you work in the dark when the arc is not running — many welders tip the helmet up between passes to see what they are doing, which defeats the point when a stray arc strike can happen unexpectedly.
Passive filters are well-suited to production environments where welding is continuous and there is no need to frequently reposition or inspect the weld between runs.
Auto-darkening filters (ADF)
An auto-darkening filter starts in a light state (typically shade 3 or 4) and switches to a dark state in 1/25,000 second or faster when the arc sensors detect a strike. This means you can see what you are doing right up until the arc fires, without lifting the helmet.
The practical benefit is speed, accuracy, and reduced neck strain from repeatedly flipping a fixed helmet. For out-of-position welding, tig welding, or any work requiring frequent repositioning between passes, an ADF helmet is the better choice.
Welding Goggles vs Welding Helmets
| Protection Type | Best For | Not Suited To |
|---|---|---|
| Welding goggles (filter goggles / gas welding goggles) | Oxy-acetylene work, brazing, silver soldering, light gas cutting. Shade 3–8. Provide side protection not possible with a face shield alone. | Stick, MIG, or TIG welding — the arc intensity is too high and spatter coverage is insufficient |
| Fixed-shade welding helmet | Production stick and MIG welding where arc-on time is high and repositioning is minimal. Lower cost entry point. | Frequent repositioning, TIG welding requiring precise torch placement, situations requiring clear vision between passes |
| Auto-darkening helmet | TIG, pipe welding, out-of-position work, fabrication with short arc-on intervals, training environments | Budget-constrained settings where a fixed passive helmet is adequate |
| Face shield + filter plate | Secondary protection for bystanders, overhead inspection, processes requiring full face coverage with a lighter frame | Sole protection for primary welding operators |
For oxy-acetylene work, goggles are generally preferred over a helmet because the flame arc does not produce the spatter pattern that a helmet is designed for — and the goggle form factor maintains better side seal and visibility for manipulating the torch and rod simultaneously.
Choosing an Auto-Darkening Helmet: What the Specs Mean
Auto-darkening helmets vary significantly in quality and specification. The key numbers to understand:
Switching speed
The time from arc strike to full dark state. Entry-level helmets: 1/3,000 to 1/10,000 second. Quality helmets: 1/25,000 second or faster. Slower switching means momentary unprotected arc exposure with every strike — over a full working day, this accumulates into meaningful UV exposure. For professional use, target 1/25,000 second or better.
Shade range
Most ADF helmets offer a variable shade range, typically 9–13 or 9–14. A wider range means the same helmet covers stick, MIG, and TIG welding across most common amperages. A fixed shade of 11 or 12 is more common on entry-level units and limits versatility.
Shade in light state
Standard light state is shade 3 or 4. This matters when setting up your weld position — shade 4 gives better natural light visibility than shade 3, which is useful in dim conditions.
Number of sensors
Most entry helmets have two arc sensors, positioned in the top corners of the lens. Four-sensor helmets are better for out-of-position welding where sensors may be partially obstructed — a two-sensor unit can fail to trigger when a sensor is blocked by the workpiece or your arm, leaving the lens in the light state during an arc.
Solar vs battery power
Solar-assisted helmets use a combination of solar cells and a lithium battery. They are generally more reliable in outdoor use. Battery-only units require monitoring and replacement — a flat battery typically causes the helmet to fail to the dark state (safe), but this can happen at inconvenient times.
Optical clarity class
AS/NZS 1338.1 rates optical quality across four parameters: optical class, diffusion of light class, variation in luminous transmittance class, and angular dependence class. Premium helmets achieve a rating of 1/1/1/1 — the highest optical clarity available. Entry-level helmets are typically rated 1/2/2/2 or 1/2/1/2. If you are TIG welding with fine arc control requirements, optical class is worth paying for.
Replacement and Maintenance
A welding helmet or set of goggles is not a lifetime purchase. Key maintenance points:
- Outer cover lens: Replace whenever pitted, scratched or spattered. A damaged outer lens distorts vision and the pits can act as stress points under impact. These are consumable items — keep a stock on hand.
- Inner cover lens: Replace when fogged or discoloured. Discolouration in a passive filter lens changes its shade rating and reduces UV/IR protection.
- Auto-darkening filter: Check darkening function before each use. Hold the helmet up to sunlight or a fluorescent lamp — the lens should darken immediately. If it does not, do not weld in it.
- Headgear and suspension: Worn headgear causes the helmet to move during welding, breaking the face seal. Replace when the retention is no longer firm.
There is no mandated expiry date for welding helmets under AS/NZS 1337.1 (unlike hard hats under AS/NZS 1801). However, most manufacturers recommend replacing auto-darkening filter cells every five to seven years as the electrochromic layer degrades.
Wider Welding Safety
Eye protection is one layer of a broader welding safety framework. Fume control, electrical safety, fire prevention, and respiratory protection are equally important in a compliant welding environment. For a full overview of welding hazards and Australian regulatory requirements, see our welding safety FAQ.
Browse AIMS Industrial's range of welding equipment and safety products, including helmets, filter lenses, goggles, and replacement cover lenses.
Frequently Asked Questions
What shade lens do I need for MIG welding?
For MIG welding (GMAW), the recommended shade depends on amperage. At 60–160 A, use shade 11; at 160–250 A, use shade 12; at 250–500 A, use shade 13–14. The minimum shade under AS/NZS 1338.1:2012 is shade 10 for 60–160 A and shade 13 for 250–500 A. When in doubt, go one shade darker — a darker shade never reduces protection, only visibility.
What is the difference between AS/NZS 1337.1 and AS/NZS 1338.1?
AS/NZS 1337.1:2010 covers the physical construction of eye protectors — impact resistance, optical quality, frame coverage, and marking. AS/NZS 1338.1:2012 covers the performance of welding filter lenses specifically — shade numbers, UV transmission limits, and infrared blocking. A compliant welding helmet should meet both standards: 1337.1 for the frame and 1338.1 for the filter lens.
What shade do I need for TIG welding?
TIG welding (GTAW) at under 50 A requires a minimum shade 8, with shade 10 recommended. At 50–150 A, use shade 10–12. At 150–500 A, use shade 12–14. TIG arcs are intense for their amperage because they are highly concentrated — do not under-shade TIG based on lower amperage compared to MIG or stick work.
Can I use a welding helmet for grinding?
Not as your primary protection for grinding. Grinding does not require a welding filter shade — it requires a clear impact-rated lens. A dark welding shade makes grinding hazardous by reducing visibility. Wear impact-rated safety glasses or a clear face shield for grinding. Many welders keep a pair of safety glasses inside their helmet for exactly this purpose.
What is arc eye and how do I prevent it?
Arc eye (photokeratitis) is ultraviolet burn of the cornea caused by exposure to welding arc radiation without adequate protection. Symptoms — extreme pain, light sensitivity, the sensation of grit in the eyes — typically appear 6–12 hours after exposure. Prevention is straightforward: always wear the correct shade filter for your process, never look at an arc with bare eyes even briefly, and ensure bystanders cannot see the arc unprotected. If arc eye occurs, see a doctor — it is painful but usually resolves within 24–48 hours with correct treatment.
What shade is safe for oxy-acetylene welding?
Oxy-acetylene welding requires shade 4–8 depending on the tip size and flame intensity. Light work with a small tip: shade 4–5. Medium work: shade 5–6. Heavy work with a large tip: shade 6–8. For oxy-cutting rather than welding, shade 3–5 is typically sufficient. Oxy-acetylene goggles are the standard form factor for this work rather than a welding helmet.
How often should I replace my auto-darkening welding helmet?
There is no fixed expiry under AS/NZS 1337.1, but most manufacturers recommend replacing the auto-darkening filter cell every 5–7 years as the electrochromic layer degrades. Replace outer cover lenses whenever they are pitted, scratched or spattered — these are consumable items. Before each use, test the auto-darkening function by exposing the sensor to bright light: the lens should switch to dark instantly. If the darkening response is slow or absent, replace the helmet before welding.
Do welding goggles offer better protection than a helmet?
For oxy-acetylene and brazing work, goggles are often preferred because they provide closer fit, better side coverage, and allow simultaneous visibility of torch and workpiece. For arc welding processes (MIG, TIG, stick), a welding helmet is the correct choice — it provides full face coverage against spatter, heat and radiant energy that goggles cannot match. The right choice depends on the process, not a general comparison of superiority.