Welding
What is welding?
Welding is the process of joining metals by melting the base materials and (often) a filler to form a fused, high-strength joint as it cools. Common processes include MIG/GMAW (wire feed with shielding gas), TIG/GTAW (tungsten electrode with precise heat control), and Stick/SMAW (flux-coated electrodes). Safe welding requires the right PPE—helmet or goggles with the correct shade, gloves matched to the process, flame-resistant clothing, and, when ventilation is limited, respiratory protection.
What welding safety gear do I need for MIG, TIG, and stick welding?
At minimum, every process requires eye and face protection (helmet or approved goggles), hand protection (heat- and cut-resistant gloves), flame-resistant clothing, and—when applicable—respiratory protection. Many shops also add cutting and gas-handling welding equipment such as torches, regulators, and hose kits.
- Welding helmets with appropriate lens shade
- Welding filters (passive or auto-darkening plates) matched to the process current
- Welding glasses / safety goggles for grinding and prep, and for oxy-fuel
- Welding gloves sized for dexterity and heat level (MIG, TIG, stick)
- Respiratory kits & components when ventilation is limited or fume levels are high
Which welding helmet shade should I use?
Shade selection depends on process and amperage. As a quick guide, SMAW (stick) and FCAW typically require darker shades than TIG at low amps, while high-amp MIG needs the darkest settings. Variable auto-darkening filters simplify selection by covering a wide shade range with a single lens.
Auto-darkening vs. passive welding helmet — which is better?
- Auto-darkening: Sensors detect the arc and darken instantly, improving visibility for joint setup and tacking; ideal for frequent repositioning.
- Passive (fixed-shade): Simple and durable; preferred by some for high-heat, repetitive work. Swap plates to change shade.
What are welding filters and shade plates used for?
Welding filters block IR/UV and visible arc intensity. You’ll find fixed-shade plates, variable auto-darkening cartridges, and accessory cover plates. Match your filter to process current, and replace cover lenses whenever pitting or spatter reduces clarity.
Do I need welding glasses or goggles if I already use a helmet?
Yes, for non-arc tasks. Welding glasses/goggles protect against grinding debris, cutting sparks, and oxy-fuel flare. Use the appropriate impact rating and, for oxy-fuel, the correct filter shade for cutting or brazing.
Which welding gloves should I choose—MIG, TIG, or stick?
- TIG gloves: Thin, supple leather for high dexterity and precise filler control.
- MIG gloves: Medium padding with heat protection and good grip.
- Stick gloves: Heavier insulation for high spatter and temperature exposure.
Select glove size for a snug, secure fit—too loose reduces dexterity; too tight increases heat transfer.
When is a welding respirator or PAPR system required?
Use respiratory protection when ventilation cannot keep fume levels below limits, when welding on coated/galvanized materials, or in confined spaces. Powered Air-Purifying Respirators (PAPR) provide filtered, positive-pressure air under a compatible helmet or hood; half-mask respirators fit under certain hoods—verify compatibility.
What cutting and gas-handling equipment do welders use?
Common kits include oxy-fuel torches, cutting tips, regulators for oxygen and fuel gases, and hose assemblies. Use the correct CGA connections, check valves, and flashback arrestors, and follow leak-check and shutdown procedures for safe operation.
How do I choose welding PPE that fits correctly?
- Helmets: Adjust headgear height, crown, and tension; ensure full coverage without impeding vision.
- Gloves: Measure palm width and finger length; choose process-specific insulation and cuff length.
- Respirators: Select the right size and perform a user seal check every time you don a tight-fitting mask.
Welding safety checklist for new setups
- Confirm lens shade and sensitivity before striking an arc.
- Wear flame-resistant clothing; secure cuffs and avoid synthetics.
- Provide local exhaust or fume extraction when needed.
- Stage a Class ABC fire extinguisher and clear combustibles.
- Inspect leads, torches, regulators, and hoses prior to use.
>Welding FAQ
At minimum: a properly shaded welding helmet, safety glasses for grinding, process-appropriate welding gloves, flame-resistant clothing, and respiratory protection when ventilation is inadequate.
Match shade to process and amperage. Variable auto-darkening lenses simplify this by covering a range (e.g., Shade 9–13 for many MIG/stick applications).
Auto-darkening lenses switch from light to dark when the arc starts, helping with positioning and tack welds. Passive helmets use a fixed shade plate, simple and rugged, but you lift and nod to view the joint.
Use a respirator or PAPR when ventilation is poor, fume levels exceed limits, or you’re welding coated/galvanized metals. Always check compatibility with your helmet/hood.
TIG gloves are thinner for dexterity; MIG gloves balance heat protection and grip; stick gloves are heaviest for high heat and spatter.
Filters block UV/IR and control visible brightness. Choose the correct shade for the process and replace damaged cover plates to maintain clarity.
No. Glasses or goggles are for grinding and oxy-fuel work. Arc welding requires a helmet or approved arc-rated eye protection with the correct shade.
Adjust headgear height, crown angle, and band tension so the shell covers your face and neck without shifting. Ensure full vision through the lens with comfortable balance.
Use oxygen and fuel gas regulators matched to the gas type and cylinder connection, with check valves/flashback arrestors and hoses rated for the service.
Replace cover plates whenever pitted or scratched; retire gloves when the leather thins, seams fail, or heat protection is compromised.