Can You Weld Stainless To Mild Steel? How To Do This?

The most common steel forms are stainless and mild steel due to their high strength and resistance to corrosion. The main distinction is that mild steel has carbon as its alloying element, whereas stainless steel contains chromium. One query is, “Can You Weld Stainless To Mild Steel?” It is feasible to use MIG and TIG welding to join the two together and produce robust welds.

Due to the nearly identical characteristics of the two metals, welding stainless steel to mild steel is not difficult. You can get solid welds if you utilize the right filler metal and follow a good low-heat process to avoid overwhelming both parts.

Corrosion resistance decreases when stainless steel components are overwhelmed. Additionally, overheating mild steel permits carbon to migrate into the metal used for the weld. As a result, the finished bead becomes more brittle and crack-prone and has less corrosion resistance.

The best ways to weld stainless steel to mild steel, the best welding rod to use, and the best filler metal to use are all covered in this article. You also pick up some advice on how to weld stainless steel to mild steel.

Can You Weld Stainless To Mild Steel?

It is possible to weld stainless steel, even though it requires more skill than other welds. Even mild steel and stainless steel can be welded together. A strong, long-lasting weld can be created by using the appropriate tools, controlling your temperature, and using the appropriate filler material.

Weld Stainless To Mild Steel

Mild Steel Vs Stainless Steel

The first thing in learning to weld stainless steel to mild steel is familiarising the distinctions between the two metals. Regarding corrosion resistance, mild steel’s high chromium concentration shines. It is also renowned for being malleable, making it simple to mould into various sizes and forms.

On the other hand, stainless steel is far more rust and corrosion-resistant since it has a larger proportion of chromium and nickel. This makes it perfect for welding since it won’t rust or deteriorate as quickly as conventional mild steel when subjected to oxygen during welding procedures.

Welding Processes

For the welds to hold up over time without degrading or becoming brittle, specific procedures must be followed when welding stainless steel to mild iron: You should employ a wire brush or grinding wheel on each piece to remove dust from the surface before starting welding.

Before beginning the actual welding process, it’s critical to preheat both components to a temperature of around 450 degrees Fahrenheit. It is important to avoid thermal shock during welding since it can cause cracking or harm the final product.

Filler material designed for joining stainless steel or mild steel can reinforce the weld; typically, this kind of steel is made of either 309L SS (stainless) or 308L SS (mild).

How To Weld Stainless To Mild Steel?

How To Weld Stainless To Mild Steel

Collect Equipment

Assemble all of the equipment required for TIG and MIG welding first. Some of the equipment you require is for welding stainless to mild steel, while others are for welding safety. Some of the items you need are listed below.

To weld stainless to mild steel, you will need the following

  1. Defensive gas
  2. MIG welder and rods
  3. Clamps
  4. Copper brush
  5. Angle grinder

Among the necessary safety equipment is

  • Knees wad and chaps
  • A helmet
  • Safety Jacket and pant
  • Boots
  • Safety eyeglasses and Hand gloves
  • Mask or ventilator

Set The Metals In Place

It would help if you were designed for the task before beginning to MIG or TIG weld stainless to mild steel. Prepare the metals and the required welding equipment. For a flawless welding process, arrange the components properly.

  1. Wear safety equipment, such as welding boots, a full-sleeved t-shirt, heated gloves, a helmet, waterproof gloves, and respirator masks.
  2. To ensure that you employ less energy and strengthen the welds, employ protective gas. 98% argon and 2% carbon dioxide gas should be combined.
  3. Use the filler metal appropriate for welding mild steel to stainless steel.
  4. Use the copper brush to remove any metal impurities from the base metal before welding. Acetone can be used to clean almost any dirt. For cleaning, you can also use sandpaper or an angle grinder.
  5. Before welding, place the stainless and mild steel parts on a jigsaw casting bench and fixture. To prevent the metal from falling back as you weld, securely pin it to the welding surface.

The Six Steps To TIG Weld Stainless To Mild Steel

TIG welding is the ideal choice when working with thin metals. Additionally, the approach is ideal for little tasks. You must use the appropriate setting for your project while using a TIG welding machine because they have various settings. Another thing to remember is that TIG welding is typically a slower form of welding. In any case, adhere to these guidelines:

  1. Put a cutting tungsten rod into the torch. You should insert the wire, which has a diameter of around 1/16 inch, in the middle of the metal cylinder. Permit the welding rod to stray a quarter-inch away from the flame tip.
  2. Once the tungsten rod has been inserted, switch on the DC in your welder. The positive and negative settings on the TIG welding machine are called settings. Your device should be marked “DCEN” for negative settings. Make sure your welding machine is set up properly.
  3. The appropriate setting on your TIG welder is now ready to start your torch. Light the torch, then hold the flame’s tip an inch above the metal joint. Start welding at any point along the joint, holding the torch at a 75-degree angle.
  4. To heat the torch on a TIG welder, you must firmly depress a foot pedal. Fill the joint while holding the torch until the metal melts. When melting the metal, only use the amperage indicated on the panel.
  5. The filler rod must be dipped into the liquid metal when filling the joint. Move the water-soaked steel bead along the metal joint while holding the rod to your torch. Ensure the torch is fixed to prevent the filler from melting from the heat.
  6. Before removing the torch and the welded metal, give it time to cool. As soon as the joint is solid, avoid moving the metal.

Recommendations For Welding Stainless To Mild Steel

When welding stainless to mild steel, keep the following in mind:

  • To prevent accidents brought on by the heat generated during the welding process, you must have all the necessary safety gear.
  • Before casting, make sure that the metal is clean. Weak couplings result from a corroded metal basis.
  • The metal parts should be placed on a sturdy table. This is essential because if the table is weak, it will shift under intense pressure as the coarse metal is placed and joined together.
  • Refrain from holding the torch and metal alone as soon as the casting is complete. Also, hang your torch on a flat surface before setting it down in a warm location.
  • Reduce the heat when welding since too much heat will cause stainless steel to deform. To avoid this issue, ensure your amperage or heat output is low.
  • Avoid using thick filler wire or rods when welding stainless steel since they need more heat.
  • Have the proper fit-up so you may sparingly use filler material and prevent gaps. To avoid poor appearance and warping, perfect your workspace arrangement.
  • Avoid moving too slowly to avoid overheating your metal. Take this into consideration when you weld.


What will you conclude about Can You Weld Stainless To Mild Steel? It is possible to effectively weld stainless steel to mild steel if the necessary procedures are followed, and the appropriate safety measures are taken beforehand.

You can make sure your welds won’t fail early due to corrosion or thermal shock issues caused by improper preparation by taking the steps outlined above, cleaning both surfaces completely before starting, preheating them appropriately, and using a suitable filler material.

In the end, though, it’s best left in the hands of a skilled welder who knows exactly what must be done for your project’s welds to turn out correctly and consistently!

Frequently Asked Questions

Is stainless steel weldable with normal steel?

It is feasible to weld mild steel and stainless steel together. Welders can successfully combine the two materials to produce sturdy welds using appropriate procedures and techniques.

What kind of welding between mild and stainless steel is best?

Mild steel, stainless steel, and these metals can all be joined using the MIG welding procedure. MIG may be adjusted to function well with various shielding gasses and wire sizes for various material thicknesses.

Which welding rod should I use to weld mild steel to stainless steel?

The suggested alloy for welding mild steel to stainless is 309L or 309Lsi. This is true even though the stainless starting point is 304, 308, or even 316.

Can stainless steel be welded to mild steel using 316?

Carbon steel can be welded to austenitic stainless steels like 304 and 316 using MIG and TIG welding. The ideal welding method when joining stainless steel to a different metal, such as ordinary carbon steel, is MIG welding, which uses filler material.

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