How To TIG Weld Stainless Steel

How to TIG Weld Stainless Steel

The Arc welder weld aluminum with most other metals relatively quickly. It forms brittle intermetallic compounds when they are typically joined with steel, copper, magnesium, or titanium. Welding Arcs into steel or aluminum requires isolation beforehand. It is possible to accomplish this with two different techniques. Here you will learn a complete guide on How to TIG Weld Stainless Steel.

How To TIG Weld Stainless Steel

Stainless steel and aluminum welded with a TIG welder? The ability to weld aluminum and stainless steel components without creating brittle intermetallic compounds has been demonstrated with two different welding methods.

  • The two methods for conducting bimetallic transitions are different from one another. One involves using techniques that avoid creating compounds to join aluminum and stainless steel. Aside from that, it is helpful for welding aluminum and steel.
  • It’s also possible to coat stainless steel with silver or aluminum solder.

Firstly, let’s look at why aluminum and stainless steel cannot be TIG welded directly together. Then, let’s explore the pros and cons of both methods.

Why You Can’t TIG Weld Aluminum to Stainless Steel

The metals have to be close in chemical composition to ensure the best welding results. The exact amount of resistance and heat is generated when the arc passes through two sheets of metal of identical thickness. That’s why it would be simple to spot-weld two pieces of the same metal. In the same amount of metal, the liquefaction and hardening would produce an even bond. You can read TIG welding tips to upgrade your knowledge. Now the question arises that how to weld stainless steel?

Even if the metals are the same material, the heat passes through the two different thicknesses differently. In addition, welding different metals together introduces a more drastic change due to the properties of each metal. Like aluminum and stainless steel, it cannot adjust certain metals in the same way by adjusting the electrical current, exposure time, electrode material, and other factors. You should learn TIG welding stainless steel before applying it. 

Differences Between Aluminum and Stainless Steel

You can not perform TIG welding on aluminum or stainless steel due to their vastly different properties. You must learn TIG welding basics before getting into this field. Because it becomes challenging to TIG welding for beginners. But if it concerns TIG welding steel, it becomes more challenging. TIG welding is an art and you have to learn the setting chart of TIG Welding first. It is better to have stainless steel tig welders to handle the Stainless steel weld. You can also read How To Use a TIG Welder. The best part about a welder is that it is equally useful for home use.

Melting Point

Aluminum melts at 1,221 degrees Fahrenheit, while steel melts at 2,500 degrees Fahrenheit. Aluminum has an oxide layer that melts at roughly 3,700 degrees Fahrenheit, complicating the situation even further.

Service Temperature

The strength of aluminum increases with a decrease in-service temperature. When service temperature drops, steel becomes more brittle.

Thermal Conductivity

Compared to steel, aluminum conducts heat 5 times better. Welding aluminum requires a higher level of heat to penetrate it. However, higher temperatures make stainless steel more likely to warp. Aluminum oxide surfaces can also cause welding complications since they act as insulators.

Current Type

Welding aluminum with TIG requires alternating current (AC). The most common way to charge an electrode is to alternate between a positively and negatively charged electrode. The oxide layer is blasted away during positive electrode application, and during negative electrode application, the base aluminum melts.

The TIG welding process uses a positively charged electrode to weld steel using direct current (DC). The aluminum oxide layer will not be penetrated by direct current (DC) TIG welding. By combining with the partially melted oxide layer, the filler metal will produce contaminated beads. You can also purchase a Hobby TIG welder or a Portable TIG welder for more accurate stainless steel welding.

Hydrogen Reactivity

Welds in steel are susceptible to cracking due to hydrogen. It is possible to obtain aluminum welds by drawing hydrogen, which is relatively soluble in aluminum liquid, into the welding environment. The cooling and solidification of liquid aluminum cause hydrogen gas bubbles to form. It causes pores in the aluminum to form.

You can use a helium or argon shielding gas mixture to protect the weld during TIG welding against hydrogen in the atmosphere. Due to gas’ high ionization potential, it is necessary to increase the voltage to overcome the problem. After that, it is resulting in increased heat input and further complications. 

These differences lead to brittle intermetallic compounds formed when you TIG weld aluminum to stainless steel, thus weakening the join. However, due to two new techniques, it is now possible to weld aluminum to stainless steel instead of arc welding. Proconsumption also guides you on how to TIG weld Mild steel

Bimetallic Transition Inserts

You mustn’t overheat the insert since overheating effectively fuses aluminum and stainless steel. You should avoid intermetallic compounds because they are extremely brittle. In the case of stainless steel parts, the stainless steel insert has a stainless steel surface, while aluminum parts have an aluminum surface.

To create a large heat sink when you TIG weld stainless steel. We recommend you first TIG weld the aluminum to the aluminum side. A stainless steel part might be hazardous to weld to a stainless steel insert before welding the aluminum side of the insert because aluminum melts at a lower temperature than steel.

The more aluminum can dilute the heat, and the less likely the aluminum is to overheat. Keep in mind that aluminum has a five-fold higher thermal conductivity than steel. If you have a limited budget then you can get a Cheap TIG Welder

Methods of Pre-bonding Aluminum To Stainless Steel Inserts

It is impossible to TIG-weld aluminum and stainless steel without resulting in brittle intermetallic compounds. The process of making these bimetallic transition inserts might make you wonder. You can use several processes to adhere aluminum to stainless steel, but they cannot assemble the components. The TIG welders are available in a variety of price ranges including 500, 800, 1000, 1500, and 2000 also. You can buy any of them without any hesitation because these are presented by World famous professionals. 

Roll Bonding

Several aluminum sheets and several stainless sheets are passed between flat rollers and compressed until they become bonded. It is necessary to clean, scratch, and degrease the surfaces to increase friction and remove any oxide layers. It is sometimes required to heat the metal beforehand to increase its flexibility, but the metal can also be bonded cold. Moreover, It is also possible to weld the Roll Cages with TIG Welder. 

Explosion Welding

Precision explosions bond aluminum and stainless steel while the two metals’ mechanical, electrical, and corrosion properties are preserved. In addition, it does not result in bulk heating or dilution of metals since the explosion lasts only milliseconds.

Friction Welding

Aluminum and stainless steel bond because of friction when they are pressed against each other. As a result, grains cannot grow, or intermetallic compounds can be produced that are very brittle. In addition, a flash of metal results from the process, thereby covering the surfaces of the metals with dirt and debris. 

Flash Welding

You must establish a predetermined distance between the aluminum and stainless steel pieces for weldability based on their thickness, composition, and expected properties. Due to the gap between the two metals, the current application melts the metals. Afterward, they are forged together through pressure and heat. Separating the metals allows the aluminum and copper to melt without forming brittle intermetallic compounds.

Hot Pressure Welding

A process similar to friction welding and flash welding, except the heat source is the flames of an oxy-fuel torch or the eddy currents produced when an inductor coil is connected with an electrical input. Now apply the heat and pressure to the aluminum components and stainless steel components to make them one piece. Fusing at a temperature above absolute zero is not possible. 

A very brittle intermetallic compound is formed when aluminum is arc-welded to stainless steel. Using these bonding techniques, we prevent such a possibility. TIG welding can connect the two metals using inserts.

For example, this process is often employed to weld structural connections of excellent quality, including joining aluminum decks to steel platforms on ships, joining aluminum tubes with steel or stainless steel tube sheets, and joining aluminum and steel pipelines together with the help of arc welding.

Coating The Stainless Steel

In addition to welding steel to aluminum, it is possible to coat stainless steel with a welded aluminum material instead.  The process involves two steps:

  1. The hot-dip aluminizing process, in which molten aluminum is dipped into stainless steel, incorporates.
  2. The brazing process, with a layer of silver solder, is applied to the stainless steel surface.

Regardless of the method used, it must take TIG welding aluminum to a coating of aluminum care to prevent the arc from impinging upon the steel. In typical stainless steel scenarios with a protective aluminum coating, heat will form intermetallic compounds that are very brittle. 

Because they design solely for sealing purposes, it is uncommon for either of these coating processes to provide complete mechanical strength.


A variety of bonding techniques are now available for the fast bonding of aluminum and stainless steel, and it is necessary for riveting. These processes are used to drill aluminum and stainless steel components. It is done by passing a rivet through each hole. It leads to a barbell shape piece of metal that holds the sheets together. 

Since the rivet now heads on both ends, it is now possible to support tension loads parallel to the rivet’s shaft. Nevertheless, it exerts perpendicular force to the rivet shaft, which is more effective at supporting shearing loads.

For mechanical bonds, the more rivets you use, the stronger they become. Inevitably, you’ll find that each rivet occupies a particular amount of space and can only carry a certain amount of load. Intermetallic bonding, which supports an entire surface, is more powerful than this method.

Frequently Asked Questions

How do you weld stainless steel?

In addition to shielded metal arc welding (MIG), gas tungsten arc welding (TIG) and stick welding, stainless steel can also be welded with shielded metal arc and gas tungsten arc welding.

What is the best tungsten for stainless steel?

Ceriated (Color Code: Orange)

In some cases, it can also replace 2 percent thoriated electrodes, so it is appropriate for welding carbon steel, stainless steel, nickel alloys, and titanium. Welders can’t tell the difference between cerium and thorium due to the differences in electrical characteristics.

What is mild steel used for?

The carbon content of mild steel is 0.05 to 0.25 percent, so it is considered low-carbon steel as well. It can be used to manufacture auto parts, plates, wire products, and other forms of mechanical structures.

What is mild steel welding?

In both manufacturing and construction, stick welding is most commonly done with mild steel. Besides being easy to obtain and purchase, it can help you with all kinds of projects and artwork. Iron and carbon (0.33 percent) combine to make mild steel, a ferrous metal.

Which welding is used for mild steel?

With tungsten inert gas (TIG) welding, mild steel can be welded to produce a clean and precise bond.

Is Mild Steel good for welding?

The mild steels used for many welding applications offer excellent weldability, and they are also cost-effective because mild steels lack additional alloying elements. The tensile and yield strengths of mild steel filler metals are usually greater than those of the base material.

What steel is best for welding?

The industry standard for welding work performed at room temperature is low carbon mild steel. There are three types of mild steel commonly used for welding (AISI 1010, 1018, and 1020) that contain traces of carbon.


In this article, You have learned How To TIG Weld Stainless Steel. TIG welding aluminum to stainless is weak as brittle intermetallic compounds form when welding aluminum. In response, two types of joining methods have been developed. A TIG weld is more efficient than mechanically joining aluminum and stainless steel components with rivets or coating stainless steel with aluminum or silver solder rather than bimetallic transition inserts.

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