How To Weld Stainless Steel To Mild Steel? [The Easiest Way]

How To Weld Stainless Steel To Mild Steel

If you need to know how to weld stainless steel to mild steel, read this article. Although welding is a risky profession, knowing the right rules makes it easier. There are several methods of welding. But which one you choose depends on your material and the project.  

You can complete the welding by simply placing the steel over the welding table using clamps and jigs. The two most applied ways for welding are MIG and TIG. MIG welding is the right way for big projects. And TIG welding is applicable for strong welding. 

Welding is the way of assembling pieces of stainless steel. This makes the repair work easier. To know more about welding, then continue this article. Here you will find the various essential data on this subject. Here I will discuss two simple welding methods for you. 

2 Easy Techniques To Weld Stainless Steel To Mild Steel:

Here I am going to discuss 2 ways of welding stainless steel. You can follow anyone’s method depending on your type of work. However, for a low budget, you can do spot welding. It is an easy and affordable welding process.

But here, I will discuss the other 2 methods, which are relatively difficult. Stay with us to know the two welding systems! ·        

1. Assemble Necessary Equipment: 

Since welding is a risky job, it requires a number of things. Some of these are used for welding and some for safety. The subsequent is a list of the two types of equipment needed:

Tools Required: 

You require the following tools to weld stainless steel to mild steel: 

Particular Safety Gears Are Required: 

  • A full sleeves jacket and pant
  • A safety eyeglasses and hand gloves
  • A helmet
  • Knee wads and chaps
  • Boots
  • A ventilator or mask

2. Setting The Steel In Place

Before you start welding, all you have to do is prepare yourself and set up the welding tools and metals. If you do not set the steel pieces correctly, you may get in trouble during welding.

Step 1: Wear a shirt with full sleeves, full-length pants,

insulated gloves, and boots when welding. You should also wear a molded helmet

to protect your eyes and face. You can also wear a respirator mask and ear

muffs for more safety.

Step 2: Depending on the type of project you are using, combine 98% argon and 2% carbon dioxide gas. Using protecting gas allows you to apply less energy and make it stronger. 

Step 3: Look at the number on the steel to identify the type of base steel. Now use a magnet and a bench grinder to test the metal. Austenitic steel is labeled with nickel and chromium.

Step 4: Use a filler metal that is compatible with the base metal for use when welding with your project metal. Filler metal can be purchased from both online and offline stores. Avoid buying fillers that can easily crack.

Step-5: Before you start welding, clean the base metal. Rub with a brush to remove impurities from the metal and remove debris using acetone. Wear gloves at this time. Some welders can use sandpaper, angle grinder, or saws as required for cleaning.

Step-6: Select a welding method according to your project. MIG welding is right for you if you need strong joints. If the metal sheets of your project are thin, you need to make a wide and shallow joint. However, if it is difficult to reach the joint, the metal should be allowed to melt during welding.

Step-7: Arrange the pieces of steel by placing the metal

on a fixture and jigsaw casting bench before starting welding. Place the steel

piece where it will be visible. Pin firmly on the table so that the steel piece

does not fall back while welding. 

Welding Method-1: MIG Welding (4 Steps)

MIG Welding is a popular welding method for professionals. This method is followed for the welding of large projects. If you also need to weld large thicker steel, follow this procedure. The MIG welding method is described step by step below:

Step-1: Thread the wire with the reel of the MIG machine and take out the wire with the tip of the torch. Extend the wire so that it is about 1⁄4 inch outside the torch. Once the wire is set, activate the gas and start welding.

Step-2: When welding, you can start working from any end of the joint. always, hold the torch 30 angle overhead the joint edge. Keep the torch sharp so that it hits the metal pieces on the tip of the flame. When the heat is high, stop working and wait until there are smooth, controllable beads.

Step-3: Slowly move the torch to fill the joint, noting that the torch is at a fixed angle. When removing the torch, the flame of the fire will push the bead towards the joint, which will melt the surrounding metal a little.

Step-4: Now let the casting cool safely. Wait until the heat comes from the metal. On the other hand, keep the torch in a safe place to cool down. Do not shake the metal before it cools; otherwise, the joint may open. 

Welding Method-2: TIG Welding (6 Steps)

To weld thin metal, TIG welding is your best method. Although using a TIG welding machine is more complicated, it is the right process for small projects. According to your project, these machines have several settings, so you need to use the correct setting.

This welding machine will do the work slowly. As a result, it is not the right choice for professionals.

Step-1: A sharp tungsten rod must first be inserted into the torch for welding in the TIG method. The tungsten rod will have a diameter of about 1⁄16 inch which must be placed in the center of the metal cylinder. Let the rod protrude 1⁄4 inch from the tip of the torch.

Step-2: After installing the tungsten rod, turn on DC in the welder. TIG Welder has two settings, positive and negative. The machine should be labeled as “DCEN” for negative settings. Make sure your setting is correct for welding properly.

Step-3: Your machine is ready to start the torch if the settings are correct. So, turn on the torch and hold the tip of the torch about 1 inch above the joint. You can start welding from any end of the joint. Always hold the torch at a 75-degree angle when welding this method.

Step-4: The TIG welding machine has an attached foot pedal; press hard on the pedal to heat the torch. Hold the torch and fill the joint until the metal melts. Your torch is not strong enough if the liquid metal is a splatter. So, you have to turn on the amperage on the panel. Please do not use too much energy to melt the metal.

Step-5: The filler rod should be dabbed into the liquid metal while filling the joint. Hold the filler rod against the torch and push the liquid steel bead along the joint. When welding the joint, dab any end of the filler rod on the liquid metal for a few seconds. Keep the torch fixed at this time; otherwise, the filler may melt in the heat. 

Step-6: Allow cooling before removing the welded metal and torch. Do not move the metal until the joint is stiff. Hold the jigs together when the metal has cooled completely and undo them. And place the torch directly on a holster until cool.

5 Tips For Welding Stainless Steel To Mild Steel Safely:

Keep in mind a few things when welding stainless steel:

  1. You must have the necessary security equipment. It is significant to defend yourself before doing any work.
  2. Do not use any welding material that could cause an unwelcome coincidence.
  3. Make sure the metal is clean before casting. If the base metal is dirty, then its joint will not be hard.
  4. Place the metal pieces on a sturdy and sturdy table. This is because if the table is not strong, it can be removed if pressure is applied during the placement and welding of coarse metal.
  5. Do not hold the metal and torch empty-handed until the casting is finished. And try to keep the torch hanging in a warm place without leaving it on a flat surface. 

Frequently Asked Question:

Which Stainless Steel Welding Method Is Best?

The stainless-steel welding method is contingent on your economic condition. If the budget for your welding is very low, you can do spot welding. Another process of welding is TIG welding which is applicable for thin steel.

Another welding process is MIG welding which is applicable for heavy metals. It is the right method for you if you work on a big project. Welding this method is somewhat expensive. This is the most popular method for welding stainless steel.

Can You Weld Stainless With Normal Wire?

The right wire should always be used for welding stainless steel. Many people may decide to use it for this purpose, but it is wrong. This is a dangerous welding method. 

Since stainless is an expensive material, it is best not to use it generally, as it can damage the stainless. If you want to weld it in a small project then you can use ordinary wire and C25 gas. This will help you to weld stronger. This is also a more inexpensive option.

What Welding Rod Is Best To Weld Stainless To Mild Steel?

Welding is the only way to repair furniture made of stainless steel. But for proper welding, you need to use a good quality welding rod. I recommend using E309L-16 for welding steel. It contains nickel and high chromium content, which are designed to prevent hot cracking.

The E309-16 welding rod is strong and corrosion is low. It is also characterized by temperature resistance. Also, another advantage of it is that it leaves a gorgeous bead. So, if you are looking for the best quality rod for stainless steel welding, then this is the right choice for you. 

How Does Spot Welding Work?

Spot welding is the oldest method of welding. No filler material is required for this type of welding. This allows you to multiple sheets of steel together. The welding done by applying pressure and heat to a specific area using copper electrodes is called spot welding.  

At this time, the current flows through the joints in the metal pieces, and the material melts and joins the parts together. This is the most economical welding method that can be done quickly. 

What Kind Of Rod Is Required For Stainless Steel Casting? 

A special kind of rod is needed for welding. Many people think that welding can be done with a normal rod. However, it is a dangerous way that can cause an accident. Welding rods of the same grade are used for welding.

I think it is better to use a 308 or 316 rod/wire for stainless steel welding. Avoid welding with ordinary rods for large projects as it is dangerous. So, I always recommend welding using the right rod.

What Type Of Wire Is Perfect To Use For Stainless Steel Welding?

Welding is the method used to repair metal furniture. At this time, it is better to use a good quality wire. If you do not know how to choose the best wire for light steel welding, choose E309L-16 without any worries. It is an excellent quality wire for welding. 

This welding wire contains nickel and chromium. It can prevent excessive heat cracking so you can weld it safely. This flexible welded wire also has high strength, which leaves a beautiful bead with corrosion and heat resistance.


Hopefully, now you have no questions approximately how to weld stainless steel to mild steel. Since welding is a dangerous profession, pay attention to personal safety. Also, keep all the necessary tools for welding at hand. And follow the correct welding method to avoid any kind of welding problem.

You can choose a welding method that suits your plan according to your economic condition. Since I have discussed each welding method above, you can now choose the one according to your convenience.

You may also want to read:

What Size Welding Lead For Pipeline

How To Cut Pipes For Welding

Kaosar Ahmed

This is Kaosar Ahmed. I’m the main publisher of this blog. Welding Leader is a blog where I share welding tips and tricks, reviews, and guides. Stay tuned to get more helpful articles!

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