TECHNIQUES FOR WELDING WITH DIFFERENT METALS

Metal fabrication professionals use welding to create parts and finished products for a wide range
of industries. Certain welding materials tend to form bonds more easily than others. The best metals
for welding depend on the project in question and the technique used. This overview of the best
welding materials will provide a brief explanation of each metal’s suitability.

Welding involves multiple techniques suited to different applications and materials. The most common
welding processes include:

 Resistance welding
 Shielded metal arc welding (SMAW)
 Gas metal arc welding (MIG)
 Gas tungsten arc welding (AC-TIG or DC-TIG)
 Flux-cored arc welding (FCAW)

Each process has an approach suited to different types of metals. They each have a unique energy
source that induces fusion between the base materials. Since every metal has various melting points
and cell structures, they have better compatibility with some techniques than others.

STEEL AND STAINLESS STEEL

Most suitable welding techniques: SMAW, DC-TIG, MIG, FCAW, resistance

Iron-based metals such as steel and stainless steel tend to work with the highest number of
techniques compared to others. Low carbon mild steel acts as one of the most weldable metals
available. Its composition includes low amounts of elements that can decrease the risk of a failed
weld. Stainless steel has a more complex chemical composition, but it can also work with multiple
techniques that account for oxidation.

ALUMINUM
Most suitable welding techniques: SMAW, AC-TIG, MIG

Grades of aluminum that fall in the 1XXX and 6XXX series can undergo select welding techniques. A
1XXX series aluminum does not require much extra effort during the welding process, making it
simple to handle. Meanwhile, a welder can work with 6XXX aluminum if they use proper welding
operations and filler material.

TITANIUM
Most suitable welding technique: DC-TIG

When a welder protects titanium from oxidation, they can use it to achieve sturdy and long-lasting
results. Titanium requires full coverage from a shielding gas to provide a high level of weld integrity.
CAST IRON
Most suitable welding technique: SMAW

Cast iron poses more difficulty during the welding process than metals such as steel or aluminum. Its
high carbon content requires careful preheating and heating methods that provide gradual
temperature changes.

COPPER AND BRASS

Most suitable welding technique: DC-TIG

Copper and brass have high corrosion resistance that makes them useful for a variety of welding
applications. During the welding process, the welder needs to account for any alloys in the material
that cause cracks or oxidation.

MAGNESIUM ALLOY
Most suitable welding technique: AC-TIG

A magnesium alloy has similar properties to aluminum. The magnesium in the alloy has a much lower
melting point than oxides, making it critical to remove oxides before welding.