Emous towering, skyscrapers, tunnels, bridges and other infrastructure everywhere metal is used in construction. Welding plays a necessary part in every construction project of impressive buildings or towers. Most people know about welding but they don’t know the difference between good weld vs bad weld. There are different types of welding operations nowadays and you should know about them.

Because there are some newbies in this profession that don’t have expertise in how to do good welding. Therefore, it is vital to know the difference between good and bad welding. It will help you to choose an expert welder and welding quality. With many other factors that affect the welding quality, it is also vital which welding helmet is used in the welding operation. Because welding helmet has a great impact on quality welding. This guide will be very helpful for you in knowing the welding quality and the difference between good welding and bad welding.

Different Kinds of Welding Operations

There are various welding processes, varieties and ways to differentiate the quality of the weld. So, it is significant to understand different welding operations and how to check their quality. Because there are some variations in different kinds of welding.

Therefore the criteria for choosing good weld vs bad weld varies. Here we discuss all kinds of welding and how to decide whether it is good welding or there are defects in welding operations. You can also check detail of undercut welding that is also an major kind of bad weld.

Stick Welding/Arc Welding

Most common and one of the easiest methods of welding are stick welding or arc welding or SMAW. Stick weld can work with various materials like alloy, carbon steel, stainless steel, copper, iron, and aluminum.

Good Stick Weld Signs

A good stick weld always has a right and consistent texture at the end. A good weld should depend on the density of the steel and should not change, and also there should be no holes, cracks or drops of spatter.

Bad Stick Weld Signs

But if you see there are noticeable spatters or cracks, or an inconsistent or undercutting width of the bead, it clearly shows that you have a bad weld vs a good weld.

TIG Welding

TIG stands for tungsten inert gas welding. TIG welding is a very tricky and complicated method as compared to stick welding. Because it needs extra accuracy and skills to attain a process. TIG welding can be used in various types of metals such as aluminum, magnesium and stainless steel. A good TIG welder can achieve the welding process perfectly, but an unprofessional welder also leaves uncertain patterns on the steel or any metal.

Good TIG Weld Signs

A good TIG weld will always seem neat and smooth. If you weld small layered to create a pattern in the weld and if your weld doesn’t have any dust powder or burnout it should be considered very good welding vs bad welding.

Bad TIG Weld Signs

Though, even if you found a horizontal bead without any different pattern, it shows that your TIG weld is done poorly. You must refurbish it because you want to see clear patterns of layered welds, no misalignment and even no burnout.

MIG Welding

MIG welding is also the easiest and most common method of welding. MIG stands for metal inert gas because the welding gun provides energy to an electrode wire to work as the filling of metal that unites elements of metal altogether. Many people are taking up limited training in metal inert gas MIG welding.

Although the process is very simple, it still can result in bad welds if you do not follow the welding procedure properly. MIG welding is mostly used on delicate metals like aluminum and mild steel. Also, check the best MIG welding helmet.

Good MIG Weld Signs

A good MIG welding always must be upright and uniform. There will be no cracks or holes, with no breakage in the weld. But if your weld is extremely delicate and has holes on the bead, it shows that the welding task requires mending again.  As compared to TIG weld, MIG weld accomplishes without any difficult patterns. Always make sure that the welding conclusion is steady and exact.

Bad MIG Weld Signs

Unstable or breaks in the weld are indications of bad MIG welding. The weld will need smoothness if there is no accuracy, and also the weld could not have sufficient stability if the bead turns out extremely delicate and tiny. These all points are signs of bad welding vs good welding.

Oxy Welding

Oxy welding is used for maintenance and also for the cutting of metal. Oxy welding is not common as compared to the other weld methods. It is always used for complicated and tricky welding and also used for delicate metals such as bronze, aluminum and copper.

Good Oxy Weld Signs

The best way to spot a good weld vs a bad weld is to look for uniformity. There must be no holes or no indications of melted metal left behind.

Bad Oxy Weld Signs

If you identify bad oxy welding, you will find holes and disarrayed patterns in oxy welding. It is a sign of bad welding vs good welding.

Factors Decide Welding Quality 

Whatever process you used for the welding task. Always ensure quality and stability are the most significant standards to decide whether it is a good weld or a bad weld. If a welding task is of poor quality so it could not be as powerful.

Weld Size

The first way is to tell if your weld is good by its size. The weld is in a consistent size from point A to point B. On the left side, the weld is not constant and not evenly smooth. It shows bad weld vs good weld.

Gas Coverage

In wire fodder welding, argon and helium gas are mainly used to conserve the base metal from getting infected by the impurities in the air and most of the time also work as an arc stabilizer. There is a possibility that the base metal could be polluted and controlled to porosity if the airflow is too heavy and the shielding gas is allocated.

Accuracy

The welding task is completed perfectly by the layout measurements. Make sure the welding job gives the necessary process and stability with safety. The look of the welding task fulfills the necessary level of your products. No breaks or craters begin in the bead. Always make the bead have consistent spirals with smooth width and accurate height. It is the indication of good welding vs bad welding.

Porosity

Welding porosity is a welding deformity or deficiency. That is found from detested or unnecessary gasses existing inside the molten weld reservoir during the process of solidification. This causes cavities or pores to appear on the surface or inside the bead. Porosity can arise on the body of a weld or inside the weld bead showing the bad weld vs good weld.

Appearance And Finishing

The complete output of welding always fulfills the design measurements and has nearly no contortion. Good welding vs bad welding satisfies the mandatory stability of the product. By using entire penetration welds that melt and meet the full functionality between the core substances or weld hookups, limited penetration welds should be utilized properly to secure the essential rigidity of metal.

Conclusion of Good Weld vs Bad Weld

Welding is an ability and talent that everyone learns to proceed further. You can choose an inexpensive welder for a little bargain and start understanding how to weld on your own with the help of using the internet as a mentor. However, once you start creating welds by yourself, it could be hard to measure their quality and integrity. Welding is a largely crucial part of the construction system. It can be valuable if you need to build or renovate any metal ventures. It is necessary to understand the various welding methods and new technologies.

FAQs

What process will follow before proceeding to weld metal in gas welding?

Whenever you proceed to weld your product by gas welding, first you should completely heat your object properly and then process weld by gas welding. This process makes your weld strong and gives strength and stability. It is the sign of good weld vs bad weld.

How would you avoid electric shock during welding?

Always secure yourself from the welding work and your ground area because the work area and metal are good electrical conductors. Wear proper defensive and protective equipment and tools, such as rubber pads, gloves, rubber boots and shield screens. If you are performing arc welding in moist or humid circumstances wear welding rubber gloves.

How would you identify good welding vs bad welding?

There are several signs or appearances to specify the good weld vs bad weld. If your product weld is thick, and smooth with accuracy and stability, it means you mend your product with a good weld. A thin layer of weld gives an uneven surface and bad weld. A good weld is always finished with no craters and holes and looks perfect. Making the bead have a consistent wave with smooth width and proper height is also the sign of a good weld vs a bad weld.

How can I determine the metal to obtain good welding?

To specify a good weld vs bad weld, you also understand the category of metal that you want to weld and what the welding method is acceptable for it to obtain good welding vs bad welding.

Underwater welding is the process of welding at elevated pressures, normally underwater. This type of welding is also known as hyperbaric welding. It is performed while the welder is submerged, often at elevated barometric pressures. The two categories considered are dry welding and wet welding. In dry welding, the welder welds in a dry environment and creates it by placing a hyperbaric chamber. In wet welding, the welder dives into the water to do welding using a specially designed welding rod. You should keep one thing in mind underwater welding is not an easy task, many welders die during this job. Here we discuss the death rate for underwater welders in detail.

Death Rate for Underwater Welders and their Life Expectancy

Do you wonder about the life expectancy of underwater welders??? Well, due to the high chances of fatalities, it is short! The previous research found the estimated average age of an underwater welder to be 35-40 years, as compared to the general human life expectancy to be 72.6 years. The high risks causing long-term injuries or deaths impute to it. Welding itself can be a threatening profession and combined with the dangers of diving into deep seawater, the certainty of injury and death worsens. Not for the faint-hearted, the job requires not only elevated skills and expertise but also hard-headedness, focus and infinite concentration.

Underwater welding jobs offer the most attractive salaries because of high fatality rates. There is also an imperative question of how much underwater welders make in a year. According to commercial divers and global statistics, the average welding underwater salary is $53,990 annually and $25.96 per hour. Most of the incomes hover around $25,000-$80,000. Diver welders in the top make $83,730 while the extremity drags $30,700. In a total population of about 10,000 underwater welders, the scope of work is huge and hence the salary is almost guaranteed.

Because the death rate for underwater welders is high compared to other kinds of welding and other professions. Therefore, it is ranked as America’s deadliest maritime job and occupation. The work requires the divers to have extensive training and experience to follow specific safety protocols before and while performing the tasks. In addition to receiving highly specialized training, welders should be kept under strict supervision and given appropriate and well-maintained equipment. The death rate should be a guiding principle to know the liability and necessity of trade.

How Often Do Underwater Welders Die?

You are still scratching your head, wondering whether this job would work for you. Well, due to the high hazard connected to the trade, the safety statistics are denoted by a welding underwater death rate. Out of 3000 full-time welders, 5 lose their lives annually. This translates into about 50 deaths out of 1000 in underwater welding life expectancy term of a welder. And this is pretty high!

However, with the advanced use of technologies and safety protocols, the death rate of underwater welders has gone down. As per older records and present statistics, around 11 underwater welders die each year. As this profession is attached to hazards, for any diver, there are risks of decompression sickness, hypothermia and drowning in the event of an equipment failure. Welders are posed with the danger of electric shock, muscle aches, memory issues and cognitive ability.

Because the diligence of the job can be pretty demanding and the risks can be many, we’ll clarify the risks welders face every day and explain how incidents happen and point out a few critical notices to be considered fully. By the end of the article, you’ll become acquainted with and be able to tell it is worth the risk!

Why Do Underwater Welders Die?

 Underwater welders face many risks every day. Here we point out some causes of the high death rate for underwater welders.

• Decompression sickness
• Hypothermia
• Drowning
• Electrocution
• Environmental hazards
• Explosion fatalities

Underwater welders also face various environmental risks, equipment failure and underwater welding accidents.

Decompression Sickness – Barotrauma

Decompression sickness also called generalized barotrauma or the bends refers to injuries caused by a rapid decrease in the pressure that surrounds you, of either water or air, while moving between different pressure zones.

Divers use extra oxygen and nitrogen, where nitrogen and other harmful gases dissolve in the blood. As the diver swims back to the surface, water pressure changes. If water pressure changes too quickly, nitrogen separates from the diver’s blood. That way, nitrogen forms bubbles in blood and tissue. Dangerous bubbles causing decompression sickness are the leading cause of fatality. The symptoms are:

• Weakness in the extremities
• Pain in the joints
• Excessive fatigue
• Numbness and tingling
• Headache

Treatment is usually hyperbaric oxygen therapy in a recompression chamber and has a high recovery rate if treated early.

Hypothermia – Exposure to Colds

It occurs when your body loses heat faster than it can produce heat, causing a dangerously low body temperature. During deep commercial diving where welders spend hours in the water, their bodies are exposed to cold temperatures. Low temperatures can be dangerous when breathing the oxygen and helium mixtures.

If there is no adequate gas heating for an extended period, lings can freeze and the diver may suffer from hypothermia. The temperature of the body goes below 95F. Specific physiological symptoms occur like confusion, organ failure and respiratory problems; some of them can even be fatal. As a safety measure, underwater welders should always wear a properly insulated rubber wetsuit.

Drowning

It can even happen to professionals. The biggest and the leading cause of death rate for underwater welders even today is drowning. Trust me when I say! Even experienced underwater welders can drown. Even by following all the safety protocols, welders can get entangled or pinned by their welding equipment when visibility drops as they dive deeper into the water. There was a scientific study where 947 diving accidents between 1992 and 2003 were monitored. The study shows that 70 victims who drowned died because of diving-related injuries, equipment malfunctioning, air supply issues and cardiac arrests.

Even today drowning occurs if you have a pack full of oxygen tank to wear all the required safety equipment. To reduce the risk you should stay hydrated, make sure you don’t work tired and keep inspecting your oxygen tank. The differential pressures present a unique risk to the divers, as they are not easy to detect. Once you become trapped in the flow, it becomes hard to escape. Sometimes, drowning can be caused by poorly maintained or old gear such as an oxygen tank, mask or hose.

Electrocution – Death Due to Electric Shock

The link between electricity and water is the first thing considered when talking about underwater welding. Even though the water itself is not a good conductor, seawater contains ions of salts and metals that increase conducting properties. Welders use either alternating current (AC) or direct current (DC) power supply, insulated electrodes and the required equipment. To avoid any type of accident you must test your welding helmet before any kind of welding operation.

But, keep in mind that wet welding is a much more exact science. So before welding underwater, divers take all the necessary precautions while joining metals in water. Safety measures include extra protection, a rubberized dry suit, and specialized waterproof equipment. In addition, safety measures make commercial diving pretty safe from electric shock.

Keep in mind that underwater welding jobs also include salvage, inspections, and material installation. Therefore, all of the named jobs can be considered underwater construction. Defense Technical Information Center (DTIC) conducted a study that shows that only one underwater welder died due to electric shock. This incident occurred in 1943 in the Deep-Sea Diving School.

All workplaces must be waterproof and properly insulated. Three factors that are responsible for causing electric shock in welders are:

1. Failure in welder’s equipment.
2. Faults and interruptions in the grounding cable.
3. The diver positions himself between the fault and the earth’s ground.

Environmental Hazards

Welders underwater work in many different environments, including offshore oil rigs, dams, oceans, lakes and rivers. Unfortunately, every single environment contains potential dangers that less experienced welders are not ready to deal with. One scientific study shows that 36% of underwater welding deaths occurred because of difficult water conditions. These are some of the factors that increase commercial diving risks, reduce their life expectancy and increase the death rate for underwater welders.

• Rough water conditions
• Underwater obstacles
• Explosions
• Strong currents
• Poor visibility
• Surges in a wave movement

Underwater welders operate in some of the most extreme depths imaginable, down to 2500m (8200ft.). These unnatural operating depths may expose divers to a host of operating complications such as:

• Impaired judgement
• Reduced visibility
• Increased air consumption
• Nitrogen necrosis
• Slower buoyancy compensator response
• Decompression sickness
• Hypothermia

Explosion Fatalities

One of the rare but potential hazards of underwater welders’ death is explosions. They occur once hydrogen and oxygen combine in the surrounding water, creating gas pockets. Once they ignite, gas pockets will cause an explosion. In addition, fuel stored in marine vessels and offshore oil rigs can also ignite and lead to death or severe injuries.

Read More: Why Underwater Welding is so Dangerous

Differential Pressure (Delta P Deaths)

Differential pressure is responsible for 7% of all reported underwater welding accidents. So that rate puts this hazard on top of the list. Delta P is standard when water moves from a high-pressure to a lower-pressure area. Accidents happen when welders open a valve, cut into space, or engage a pump. The height difference between the two bodies generates a suction force. Therefore, the more significant the height or pressure difference, the more dangerous the suction force is as the power is more substantial.

The biggest problem is that you cannot detect potential Delta P situations visually. It all happens very suddenly, and trying to pull out your arm or a leg, feels like trying to lift the car with it. To reduce the risk, welders must first be aware of it. When there is a potential Delta P situation in the work area, the fluid mechanic calculation will determine the safe zone. Usually, before the work, you’ll get all the required information. However, if you still doubt, you can use the Continuity Equation, Torricelli’s Equation, and the Drag Equation to calculate the safe zone by yourself.

Keep in mind that Delta P hazard is present in your domestic swimming pool or even spa, so you don’t need to be an underwater welder to be at risk. Fatalities may even occur at depths as low as 3 meters or less by the substantial suction forces present in large openings, even when there is a slight difference in water levels. Differential pressure hazards or Delta P hazards are usually identified before welding and should have the proper lockout/tag procedures in place or double isolation to protect from injuries.

Other Threats

There is also a threat inherent in marine life such as sharks and deadly stingrays for an underwater welder to fear coupled with poor visibility, welders might snag scuba equipment on underwater hazards. Likewise, pressure changes were seen during ascent and descent, strong currents, contaminated water and trappings also lead to a certain death rate in underwater welders.

Disabling injury: By the time the rescue team reaches the diver, they are already out of the air.

Triggering event: Diver’s cords are twisted.

Harmful/Disabling Event: The diver panics, which leads to breaking the line.

Host Factors: The main cause is the level of experience. Sometimes behavioral dysfunction is accounted for.

Environmental Factors: Supervisor/tender errors, equipment failure.

Underwater Welders Death Rate – How Risky Is It?

Various studies show different death rates for underwater welders. The first one was released by the Center for Disease Control and Prevention (CDC), which published the data monitored between 1989 and 1997. According to their numbers, there was an average of five underwater welder deaths in nearly ten years.

According to past OSHA reports, there are an average of 6-13 diving-related deaths every year. Unfortunately, there are no recent statistics that monitor the underwater welder’s annual death rate. In addition, OSHA safety standards on commercial diving haven’t been updated since 1978. Nevertheless, there are promises that new safety protocols are being developed and implemented every year. Still, older studies show that drowning is a leading cause of underwater welders’ deaths, while they state that approximately 11 underwater welders die every year.

While the Bureau of Labor Statistics does not track fatality rates of underwater welders, a study conducted in 2018 shows that for every 100,000 workers in the US, about 3.5 of them die on their jobs every year. The study identified five jobs that come with potential risks. Underwater welding was listed as the top dangerous profession with nearly a 15% fatality rate, followed by aeronautics with 5%, logging with 0.13%, fishing with 0.12%, and aeroplane piloting with a 0.07% fatality rate.

Conclusion:

Underwater welding offers the opportunity for travel, adventure, and lucrative pay. Salaries in underwater welding can vary widely. But it can be more lucrative than welding strictly on dryland due to the training involved, the environment they work in, and the amount of risk involved. If you are ready to take the risk, you can earn quite a few bucks. Welders that go through training reduce the risk of possible injuries and hazards. Our expert advice for all underwater welders is first to get proper training in underwater welding and gain knowledge about its difficulties. In this way, we can reduce the death rate for underwater welders.

Read More: Guide To Underwater Welding Helmet

FAQs

How many underwater welders die each year?

According to recent searches, there are about 11 underwater welders die each year. The main reason for the high death rate for underwater welding is drowning.

Is underwater welding risky?

Yes, underwater welding is more risky than normal welding. You can get an idea of it by seeing the high death rate for underwater welders.

Do underwater welders get attacked by sharks?

Normally underwater welders are safe from marine wildlife because they are conscious of marine wildlife such as sharks and other creatures.

Auto-darkening welding helmets have reshaped the welding industry. It helped to make welding an easy occupation by ensuring the safety of the welders. These welding helmets protect the skin and eyes of the operator. It fetches all of the power required for auto-darkening from the batteries. Sooner or later, these batteries have to drain out empty. When these batteries are fully drained, then it’s time to change the battery. So, if you are a professional welder, then you must know how to change the battery in a welding helmet. It will help a lot in your welding operations. 

This article will teach you about the following main aspects. 

• Why use batteries in a welding helmet?
• Time to replace the batteries
• How to Change Battery in Welding Helmet?
• How to change the battery in the Hobart welding helmet?

Let’s dive into the guide to learn more about the above-discussed headings. 

Why Use Batteries in Welding Helmet?

Welding is a game of fire, flash, and spatters. It’s a dangerous but inevitable occupation. Because there is always a need to join or cut a metal piece, all of this is usually done with the welding torch. To play the action, personal safety is much required. In the old days, this was done with the help of passive welding helmets. There is a fixed shade lens supported with the transparent lens present in these welding helmets.

Over time, in 1981 first active or auto-darkening welding helmets appeared in the market. When the welding torch touches the ground of welding, then sensors detect the lightning and darken the screen. All of the procedures are completed within a fraction of one second, which is now on average 1/25,000 seconds. This procedure is only possible just due to the presence of the batteries.   

Time has changed and present welding helmets are equipped with solar power. But the importance of batteries is evergreen like in the past. These batties support the solar system to carry on the welding operation properly. It is vital for a welder to know how does an auto-darkening welding helmet works because it helps the user to get the maximum out of it.

Time to Replace the Batteries

There are different types of welding helmets present in the market. Some welding helmets have built-in batteries. On the other hand, some welding helmets are equipped with replaceable batteries. There is a common thing between both types of welding helmets, that is, you have to replace the battery. In the case of a built-in or fixed battery, it works for a long time like 2 to 3 years. On the contrary, the second one has to be replaced sooner than the previous one.

By following proper guidelines, you can replace a battery easily. It requires both your precious time and money. So, you don’t have to throw away your old one although it’s properly working. In the following, there are a few tests that will teach you this is the right time to replace the battery. 

Take Alert System Seriously

As previously mentioned, there is an epic advancement in welding manufacturing. Helmets that are manufactured within the last few years are equipped with a signal, which alerts the user about the battery. This signal only buzzes up if the battery of your welding helmet is about to die or the course of life has ended.

One thing is that you must care about these signals. Within the past few years, there are many advanced-level welding helmets designed with low battery signals. So, check the manual to get a clear picture about the battery life, whether it is about to die or there is a need for a plugin. 

Variable Intensities

The key feature of an auto-darkening welding helmet is the adjustment of shade for different welding operations, according to the intensity of light. The reason behind the adjustment is the presence of sensors in the forehead of the welding helmet. The efficiency of bright and dark shade depends upon the strength of the welding helmet’s battery as well. Checking the welding helmet at variable intensities of light is an excellent way to check the condition of battery life.

For this test, deliberately spark up and carry on this operation. If there are many spark flashes received, then there is something wrong with the welding helmet because it is supposed to activate the auto-darkening option according to the light’s intensity. An excessive flash to your eyes is a sign of a weak battery. It means that the batteries are not responding to arc flash properly. 

Before making the final decision, you must check the sensitivity level of your welding helmet. It may be possible that you haven’t adjusted the sensitivity properly. If the sensitivity is too high then there is prolonged darkening. On the other, if the sensitivity is too low, then there is late darkening in response to high intensity of light. So, you should consider this option before making up your mind to change the battery of your welding helmet.

The Sun Test

Wear your welding helmet and go outside under the sun. This one is natural as well as easy to check. Face the sun, wave your hand between your face and sun as well back and forth on the path of your eye-sight. This one will block the sunlight intermittently, and it’s enough to trigger up the auto-darkening feature of your welding helmet. 

Now, focus on the results. If the auto-darkening is working appropriately, then carry on to your work with these batteries. Otherwise, it’s time to replace the battery of your welding helmet. You must also check another testing method for welding helmets because it will help you to make a true opinion about welding helmets.

There are two main things you must consider while performing this test. The first thing that you must have is to check the sensitivity of your welding helmet. As discussed in the previous section, too high causes prolonged darkening and too low late darkening. The second thing you must consider should be the last option to check the battery condition. 

Once all set and you are clear about the battery health. It’s time to get a replacement. Initial steps for the replacement vary from model to model. The reason behind this is the battery presence. 

How to Change Battery in Welding Helmet 

In the following, you will find the common steps to replace the battery of your welding helmet. If you are worried about reading, these steps vary from model to model. Then don’t worry about it, in the later section, you will also learn about how to change the battery in some famous brands.

Let’s see a few general steps to replace a battery in an auto-darkening welding helmet. 

Battery Selection 

You can find two situations here regarding battery selection. One is that you will find auto-darkening with the help of only the battery. Usually, Lithium-Ion Metal batteries are used in welding helmets. The second situation is that you find a welding helmet powered with both a solar system and Lithium-ion metal batteries. In some situations, you can find a welding helmet powered by a solar system but accompanied by fixed or non-replaceable batteries. Yes, batteries can be both fixed or replaceable. Replaceable is mostly preferred over non-replaceable. But to discuss the fixed or replaceable is out of context here. Let’s get back to our topic.

For the proper selection of a battery for your welding helmet, you should have a concern with the user manual that you have along with the welding helmet. Typically, AAA or AAAA batteries are required to empower the welding helmet.

Read More: Bluetooth Welding Helmet Working

Toolkit 

The second most important thing that you have to consider is, that you have to gather all of the requirements for the replacement. In the following, there is a checklist of tools required.

• Screwdriver
• Solder along with matching iron
• Dremel diamond wheel
• 3VDC cell holder

After you’ve gathered all of these things, it’s time to take action. As you get from the previous section, the place of the battery may vary from model to model. 

Locate the Battery

In most of the welding helmets battery is present besides the front lens. Therefore, examine the front portion of the welding helmet, which is located near the lens. After finding the location, the next thing is to dissect the battery. Use the Dremel tool to remove it from the place. This will not take more than a minute.

To go through a smooth and supported operation, put your helmet on the table to get some support. A Dremel tool is required to cut an area that is a small square just like the size of a post stamp. Keep the part of cut plastic to use later. After watching the battery, take a pen and pencil to note down the information like the exact place of the battery and polarity. 

Battery Removal 

This one is the most important step where you must have focused as much as possible. Take the screwdriver to lose the tabs that secure the battery at the spot. Lose them but be careful while losing them. Gentle force can break them down. Lose them according to the requirement. Apply gentle force, which is required to remove the battery, not apply brute force.

Battery Installation

Connect the battery holder with the desired leads with the help of a solder. While making the connection, you must make sure to make the right connection. Join the red lead with the positive side, and black leads with the negative side. After that, you have to make a small incision that allows the wire to run externally. 

Place the battery in the desired place in the holder. It’s time to rebuild the dissected welding helmet. For this, you have to follow the procedure that you have written on the paper. Place the holder at the desired place. Use hot glue to seal the dissected small plastic piece on the welding helmet. 

Testing

You have to test the welding helmet before putting it into operation. Follow the three tests to replace the battery. But at this time, you will feel a difference. The difference is that this time you are just checking it to put it into action, not for the sake of information about the battery condition. 

How to change the battery in the Hobart welding helmet?

Some of the advanced welding helmets, like the Hobart welding helmet, have a few unique steps for replacing the battery. For this welding helmet, you have to push the front lens inside of the welding helmet. When the front comes out from the place, you have to remove the tabs from it. After that, you will get lens assembly. If you look at the upper side of the lens, you can find a battery holder. Push it out with the help of your hand but requires gentle force. Remove the old one and place the new battery inside the holder. Reverse the operation to regain its original shape.

Read More: Welding Helmet Designs

Auto-darkening welding helmets have reshaped the welding industry. It helped to make welding an easy occupation by ensuring the safety of the welders. These welding helmets protect the skin and eyes of the operator. It fetches all of the power required for auto-darkening from the batteries. Sooner or later, these batteries have to drain out empty. When these batteries are fully drained, then it’s time to change the battery. So, if you are a professional welder, then you must know how to change the battery in a welding helmet. It will help a lot in your welding operations. 

This article will teach you about the following main aspects. 

• Why use batteries in a welding helmet?
• Time to replace the batteries
• How to Change Battery in Welding Helmet?
• How to change the battery in the Hobart welding helmet?

Let’s dive into the guide to learn more about the above-discussed headings. 

Why Use Batteries in Welding Helmet?

Welding is a game of fire, flash, and spatters. It’s a dangerous but inevitable occupation. Because there is always a need to join or cut a metal piece, all of this is usually done with the welding torch. To play the action, personal safety is much required. In the old days, this was done with the help of passive welding helmets. There is a fixed shade lens supported with the transparent lens present in these welding helmets.

Over time, in 1981 first active or auto-darkening welding helmets appeared in the market. When the welding torch touches the ground of welding, then sensors detect the lightning and darken the screen. All of the procedures are completed within a fraction of one second, which is now on average 1/25,000 seconds. This procedure is only possible just due to the presence of the batteries.   

Time has changed and present welding helmets are equipped with solar power. But the importance of batteries is evergreen like in the past. These batties support the solar system to carry on the welding operation properly. A welder needs to know how an auto-darkening welding helmet works because it helps the user to get the maximum out of it.

Time to Replace the Batteries

There are different types of welding helmets present in the market. Some welding helmets have built-in batteries. On the other hand, some welding helmets are equipped with replaceable batteries. There is a common thing between both types of welding helmets, that is, you have to replace the battery. In the case of a built-in or fixed battery, it works for a long time like 2 to 3 years. On the contrary, the second one has to be replaced sooner than the previous one.

By following proper guidelines, you can replace a battery easily. It requires both your precious time and money. So, you don’t have to throw away your old one although it’s properly working. In the following, there are a few tests that will teach you this is the right time to replace the battery. 

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Take Alert System Seriously

As previously mentioned, there is an epic advancement in welding manufacturing. Helmets that are manufactured within the last few years are equipped with a signal, which alerts the user about the battery. This signal only buzzes up if the battery of your welding helmet is about to die or the course of life has ended.

One thing is that you must care about these signals. Within the past few years, there are many advanced-level welding helmets designed with low battery signals. So, check the manual to get a clear picture about the battery life, whether it is about to die or there is a need for a plugin. 

Variable Intensities

The key feature of an auto-darkening welding helmet is the adjustment of shade for different welding operations, according to the intensity of light. The reason behind the adjustment is the presence of sensors in the forehead of the welding helmet. The efficiency of bright and dark shade depends upon the strength of the welding helmet’s battery as well. Checking the welding helmet at variable intensities of light is an excellent way to check the condition of battery life.

For this test, deliberately spark up and carry on this operation. If there are many spark flashes received, then there is something wrong with the welding helmet because it is supposed to activate the auto-darkening option according to the light’s intensity. An excessive flash to your eyes is a sign of a weak battery. It means that the batteries are not responding to arc flash properly. 

Before making the final decision, you must check the sensitivity level of your welding helmet. It may be possible that you haven’t adjusted the sensitivity properly. If the sensitivity is too high then there is prolonged darkening. On the other, if the sensitivity is too low, then there is late darkening in response to high intensity of light. So, you should consider this option before making up your mind to change the battery of your welding helmet.

The Sun Test

Wear your welding helmet and go outside under the sun. This one is natural as well as easy to check. Face the sun, wave your hand between your face and sun as well back and forth on the path of your eye-sight. This one will block the sunlight intermittently, and it’s enough to trigger up the auto-darkening feature of your welding helmet. 

Now, focus on the results. If the auto-darkening is working appropriately, then carry on to your work with these batteries. Otherwise, it’s time to replace the battery of your welding helmet. You must also check another testing method for welding helmets because it will help you to make a true opinion about welding helmets.

There are two main things you must consider while performing this test. The first thing that you must have is to check the sensitivity of your welding helmet. As discussed in the previous section, too high causes prolonged darkening and too low late darkening. The second thing you must consider should be the last option to check the battery condition. 

Once all set and you are clear about the battery health. It’s time to get a replacement. Initial steps for the replacement vary from model to model. The reason behind this is the battery presence. 

How to Change Battery in Welding Helmet 

In the following, you will find the common steps to replace the battery of your welding helmet. If you are worried about reading, these steps vary from model to model. Then don’t worry about it, in the later section, you will also learn about how to change the battery in some famous brands.

Let’s see a few general steps to replace a battery in an auto-darkening welding helmet. 

Battery Selection 

You can find two situations here in regards to battery selection. One is that you will find auto-darkening with the help of only the battery. Usually, Lithium-Ion Metal batteries are used in welding helmets. The second situation is that you find a welding helmet powered with both solar system and Lithium-ion metal batteries. In some situations, you can find a welding helmet powered by a solar system but accompanied by fixed or non-replaceable batteries. Yes, batteries can be both fixed or replaceable. Replaceable is mostly preferred over non-replaceable. But to discuss the fixed or replaceable is out of context here. Let’s get back to our topic.

For the proper selection of a battery for your welding helmet, you should have a concern with the user manual that you have along with the welding helmet. Typically, AAA or AAAA batteries are required to empower the welding helmet. 

Toolkit 

The second most important thing that you have to consider is, you have to gather all of the requirements for the replacement. In the following, there is a checklist of tools required.

• Screwdriver
• Solder along matching iron
• Dremel diamond wheel
• 3VDC cell holder

After you’ve gathered all of these things, it’s time to take action. As you get from the previous section, the place of the battery may vary from model to model. 

Locate the Battery

In most of the welding helmets battery is present besides the front lens. Therefore, examine the front portion of the welding helmet, which is located near the lens. After finding the location, the next thing is to dissect the battery. Use the Dremel tool to remove it from the place. This will not take more than a minute.

To go through a smooth and supported the operation, put your helmet on the table to get some support. A Dremel tool is required to cut an area that is a small square just like the size of a post stamp. Keep the part of cut plastic to use it on later. After watching the battery, take a pen and pencil to note down the information like the exact place of battery and polarity. 

Battery Removal 

This one is the most important step where you must have focused as much as possible. Take the screwdriver to lose the tabs that secure the battery at the spot. Lose them but be careful while losing them. Gentle force can break them down. Lose them according to the requirement. Apply gentle force, which is required to remove the battery, not apply brute force.

Battery Installation

Connect the battery holder with the desired leads with the help of solder. While making the connection, you must make sure to make the right connection. Join the red lead with the positive side, and black leads with the negative side. After that, you have to make a small incision that allows the wire to run externally. 

Place the battery at the desired palace in the holder. It’s time to rebuild the dissected welding helmet. For this, you have to follow the procedure that you have written on the paper. Place the holder at the desired place. Use hot glue to seal the dissected small plastic piece on the welding helmet. 

Testing

You have to test the welding helmet before putting it into operation. Follow the three tests that you have read at the top of this article, under the section of time to replace the battery. But at this time, you will feel a difference. The difference is that this time you are just checking it to put it into action, not for the sake of information about the battery condition. 

How to change the battery in the Hobart welding helmet?

Some of the advanced welding helmets, like the Hobart welding helmet, have a few unique steps for replacing the battery. For this welding helmet, you have to push the front lens inside of the welding helmet. When the front comes out from the place, you have to remove the tabs from it. After that, you will get lens assembly. If you look at the upper side of the lens, you can find a battery holder. Push it out with the help of your hand but requires gentle force. Remove the old one and place the new battery inside the holder. Reverse the operation to regain its original shape.

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