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3 Common Mistakes Made When

Handling Stainless Steel
July 27, 2017

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Producing components with stainless steel is a smart choice for durability and product
longevity because of its natural oxide protection layer. However, warping, corrosion, or even

metallurgical changes can occur if best practices are not used.

Metalworkers new to stainless, or even experienced welders and fabricators in a hurry, need
to pay close attention to proper stainless steel handling techniques and procedures to
maintain the integrity of the metal and keep the final product in-spec.

Find out why introducing surface contaminants is one of the riskiest blunders in handling
stainless steel and how to avoid this and other mistakes during stainless steel fabrication.

1. Metallurgical Changes

How it happens:

The Heat Affected Zone (HAZ) during the welding or thermal cutting process is larger on
stainless steel because of lower thermal diffusivity (4.2 mm2/s) compared to other
metals
This can lead to a change in grade (austenitic stainless steel turning martensitic, more
brittle and harder) or heated metal becomes weaker

Cutting Options:
In his article on HAZ, Andrea Bustreo notes the four types of cutting and factors that should be
noted in employing them during stainless steel fabrication.

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 Shearing, manual cutting and waterjet cutting do not provoke a HAZ because they
do not overheat the sheet metal.
Laser cutting generates the smallest HAZ among all thermal cutting techniques
because it applies heat on a very small area.
Plasma cutting generates an intermediate HAZ because the plasma pulse is wider

than a laser beam. Higher currents allow for a higher cutting speed, reducing the
duration of exposure and the width of the HAZ.
Oxyacetylene cutting generates the widest HAZ of all thermal cutting systems
because of the intense heat, slow speed, and wide flames.

Weld Decay:

Intense localized heat from welding can result in the depletion of chromium in the base metal
around the weld. This change in the metal makes it sensitive to corrosion. ASM International
published a paper listing these options for controlling stainless steel sensitization.

A postweld high-temperature anneal and quench to redissolve the chromium at grain

boundaries, and hinder chromium carbide formation on cooling.

A low-carbon grade of stainless steel (e.g., 304L or 316L) to avoid carbide formation.
A stabilized grade of stainless steel containing titanium (alloy 321) or niobium (alloy
327), which preferentially form carbides and leave chromium in solution.
A high-chromium alloy (e.g., alloy 310)

2. Distortion

How it happens:
Stainless steel’s low thermal conductivity and high expansion rate make it an easy target for

distortion during welding

Welding Tips:

Use lowest amperage possible without jeopardizing the weld quality

Control interpass temperatures

Use controlled tack welding, clamping jigs, or a copper backing plate

3. Introducing Surface Contaminants

How it happens:

Iron filings and other environmental contaminants come in contact with stainless steel

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 Grease on hands, chalk, and other items introduced during handling can contaminate
the surface

Both of these can lead to localized corrosion

Avoiding Surface contamination:

Use an abrasive designed for stainless steel grinding, blending, and deburring

Keep stainless steel abrasive products separate from other abrasives used on different
metals. Never use an abrasive product that has been used on a different type of metal

Store stainless steel separately from carbon steel and other metals
Keep stainless steel in packaging and protected from the elements as long as possible

Remove adhesives used in transport from the stainless steel: these can harden and

cause crevice corrosion on the site

Proper welding and cutting techniques, awareness of the HAZ, and adherence to good quality

control and anti-contamination measures will give you an in-spec, well-finished stainless steel
product. Make sure that you and your team read this article to keep common stainless steel

fabrication mistakes at bay.

To learn more about stainless steel fabrication, download your copy of A Metalworker’s Guide
to Stainless Steel.

Sources

https://www.assda.asn.au/technical-info/surface-finishes/stainless-fabrication-common-traps-

to-avoidhttp://www.thefabricator.com/article/arcwelding/common-technical-mistakes-new-
welders-make-and-how-to-avoid-them

https://www.scribd.com/document/341395448/Special-Report-Avoid-Common-Mistakes-With-
Vessels

https://www.huntingdonfusion.com/index.php/en/technical-support/technical-papers-

61691/796-mechanical-weld-backing-methods

http://www.thefabricator.com/article/shopmanagement/all-you-need-to-know-about-the-heat-

affected-zone

Filed under: Stainless Steel

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Bob Lowe 2/15/2019, 9:09:48 AM

I didn't know that intense heat could deplete chromium in the base metal. My brother is considering

going to trade school for welding and he wants to know more about how it all works. I'll have to
consider your tips so that he can get the most out of his welding education.

Reply to Bob Lowe

Sarah Smith 3/2/2019, 4:31:18 AM

It's really interesting that, when cutting stainless steel, you need to be aware of what the steel will be

used for. I would imagine that using shearing or laser cutting would be preferable for precision work
while plasma cutting would be best for industrial applications that don't need to be as precise. This

makes me wonder whether there are specialty fabrication companies that focus on cutting stainless
steel. http://kanyanaengineering.com/laser-cutting

Reply to Sarah Smith

Sam Li 3/8/2019, 3:09:44 AM

I had no idea that welding can quench to redissolve the chromium in stainless steel, so I appreciate you

mentioning that. When it comes to obtaining the proper steel products, it's essential to work with a

company that has a wide selection of materials. If I were to use steel to construct a fence, I would make
sure to contact a business in town that has the best steel materials available.

https://www.centralcoastfencingindustries.com.au/steel

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 Reply to Sam Li

Mike Lee 4/4/2019, 11:13:13 PM

We are looking into steel distributors for a project at work. It is interesting that surface contaminants

make such a large di erence, I'll have to make sure that we use the right tools for it.
https://www.advancedmetalsales.com/products

Reply to Mike Lee

Sarah Jean 5/3/2019, 1:46:14 AM

I didn't realize that surface contaminants like iron lings can lead to corrosion across the steel surface.
In my mind, this means that you can nd a quality steel fabrication service by whether they practice
grinding and deburring as you've mentioned. It would be interesting to see how steel fabrication works

from start to nish.

Reply to Sarah Jean

Hazel Owens 5/8/2019, 10:41:33 AM

That's good to know that stainless steel can become discolored and distort its shape because it has low
thermal conductivity. This is why it would be smart to hire a fabrication company that specializes in
stainless steel since it would help avoid destroying the look and shape. It would be smart to look

around and ask fabrication companies if they'd also be willing to weld for the business since they
would know how to handle it correctly. http://www.candjsheetmetal.com.au/

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 Reply to Hazel Owens

Daphne Gilpin 5/16/2019, 9:22:51 PM

Thanks for explaining that manual cutting and waterjet cutting are good because they don't overheat
the sheet metal. My husband and I need to choose a metal manufacturer to buy some steel parts from.
I'm glad I read your article because now I know a lot more about the di erent methods for cutting

steel. http://www.acmetals.com/?s=303+Stainless&post_type=product

Reply to Daphne Gilpin

John Stokes 5/28/2019, 3:57:28 PM

I agree handling stainless steel is quite tough when you have not used to it. Your steel got cut depends
on how you cut it and it got distorted if not using proper tools. Keep sharing!
To get more information go through the link https://metalscut4u.com/

Reply to John Stokes

Skyler Williams 7/30/2019, 1:53:51 AM

I had no idea that stainless steel's low thermal conductivity and high expansion rate could lead to

distortion when welding. I am new to welding and I am looking for tips. I will keep this in mind,
however, I think I will stick to using a professional company for current projects.
https://www.kjfab.com.au/specialising-in

Reply to Skyler Williams

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Elisabeth Southgate 7/31/2019, 9:47:45 PM

I appreciate you helping me learn more about cutting stainless steel. My nephew is wanting to go into
manufacturing. He will be interested to know shearing, manual cutting and waterjet cutting don't
overheat the metal.

https://www.toltecsteel.com/services

Reply to Elisabeth Southgate

Faylinn Byrne 8/6/2019, 12:34:41 AM

I never knew that laser cutting generates the smallest HAZ among all thermal cutting techniques. My
grandpa has a lot of metal sheets that he wants to cut to be able to work on a personal project, and he
is thinking of hiring someone to laser cut it. I will pass this information on to him, so he can make the

best decision. http://www.metalfab.com/laser-cutting-ny.html

Reply to Faylinn Byrne

Anuj Sharma 8/10/2019, 12:00:05 PM

Good informative article. I was seeking such kind of content. Thanks a lot!

Reply to Anuj Sharma

Kate Reilly 8/12/2019, 10:05:58 PM

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 Thank you Anuj!

Reply to Kate Reilly

Keegan Murphy 8/15/2019, 9:48:12 AM

These things are crucial because a substandard nished product could spell disaster. I hope only highly
trained professionals are allowed to do that! Thanks for this, Kate!

https://doallmetal.co/steel-metal-fabrication-works/

Reply to Keegan Murphy

Tyson Coolidge 11/19/2019, 10:40:27 PM

I like what you said about being careful when welding stainless steel so that it doesn't change in grade.
My brother has been telling me about some work that he wants to do with sheet metal in the next few

weeks. I'll share this information with him so that he can make sure that it gets done properly.
https://www.wasteel.com.au/sheet-metal/

Reply to Tyson Coolidge

Kate Hansen 12/27/2019, 2:22:25 AM

It's good to know that you need to use controlled tack welding. My husband is wanting to get into the
fabrication industry for his company so it can be easier for his projects that he does every couple of

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weeks but for now, he will need to hire a professional. I'll make sure to pass this information along to
him so he can know more about working with steel. http://curtismachine.net/services.html

Reply to Kate Hansen

Sam Li 12/31/2019, 5:23:58 AM

I appreciate what you said about weld decay. When it comes to steel shelving, it's important to nd a
reliable supplier. I'll be sure to nd a reliable shelving system for my garage.

http://www.quantumstorage.com/steel-shelving

Reply to Sam Li

Austin Saunders 3/5/2020, 11:10:49 PM

I like what you said about using low amperage welders when working with stainless steel. My sister has
been telling me about how she wants to get some new products made with stainless steel soon. I'll
share this information with her so that she can look into her options for professionals who can help
her with this.

https://www.pharmasurplusequipment.com/index.php/product/description/FITZPATRICK-DAS06-
Fitzmill-Commutator-Stainless-steel-

Reply to Austin Saunders

aluminium welding Auckland 3/19/2020, 5:05:50 PM

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Your blog 3 Common Mistakes Made When Handling Stainless Steel is amazing. I was looking for this
kind of informative post for so long. But after reading your blog I got all the information that I needed.
So I want to thank you for writing this article. Keep posting such an amazing and informative blog. I

have also found this resource Otahuhuengineering.co.nz/services/manufacturing useful and its related
to what you are mentioning.

Reply to aluminium welding Auckland

Stephen Claus 3/29/2020, 3:15:00 PM

Handling steel should be taken with precaution. Thanks for this inputs. Great Article. If you have time,
you might want to check our website https://tecm-fabrication.com.

Reply to Stephen Claus

Thomas Clarence 5/7/2020, 1:23:37 AM

I thought it was interesting when you talked about how metalworkers need to pay coles attention to
their techniques when handling stainless steel. As far as I know, stainless steel plays an important role

in the construction industry when being used in structures. It would be interesting to learn what kind
of roles this metal plays in other industries. https://www.watersbros.com

Reply to Thomas Clarence

steel welder 9/10/2020, 12:16:03 AM

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It is quite critical to handle steel welding. but you have explained it very well.

Reply to steel welder

Megan Alder 9/10/2020, 2:49:20 AM

It's interesting to know that the way you cut metal is based on its own metal material. I could imagine

that if I was to have a project that involves steel and other materials I will be very cautious with the way
I cut it. If I ever need to cut steel for a project I will make sure I follow what you recommended to cut it
safely, and successfully.
https://www.ashleysteelandsalvage.com/structural-steel-supply

Reply to Megan Alder

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