When welding stainless steel to carbon steel, the filler rod used can make or break the weld. Even the welding method, technique, and machine settings can have an impact on the outcome of the weld.
To get a good weld between these two metals, you need to pick a filler rod that has similar metallurgical properties to the two base materials when being welded together.
Stainless Steel and carbon steel are different from each other when it comes to using them in welding.
Both stainless steel and carbon steel have unique characteristics that make them more suitable for different applications.
If you are trying to identify whether can you weld stainless steel to carbon steel, read the article below for information on how these alloys work and some ways to weld them together.
Can You Weld Stainless Steel To Carbon Steel?
Welding Stainless Steel with Carbon Steel is one of the most common welding applications around. Grades 304 and 316 stainless steel are frequently welded to plain carbon steels such as AISI 10XX and 4XXX series steels and work well with both MIG and TIG techniques. For welding both dissimilar materials, I recommend going for a MIG welding procedure.
Stainless Steel is considered a form of corrosion-resistant steel because it has an oxide film that protects it from rusting.
The oxide film forms when a chemical reaction takes place between oxygen and iron or other metals in the material.
This process occurs naturally when stainless steel is exposed to air or water over time but can also be accelerated by applying heat or chemicals such as vinegar or salt solutions.
Carbon steel is a type of iron alloy with a carbon content between 0% and 2%. Carbon steel is often used in construction materials like bridges because it’s durable enough to withstand bending without cracking or breaking under stress placed on it from heavy loads like trucks driving over them every day.
However, it’s not as resistant to corrosion as stainless steel because it’s not protected by an oxide layer as stainless does once exposed.
For a better understanding of welding stainless steel to carbon steel through MIG & TIG processes, read the full article!
Can you Weld Stainless Steel to Regular Steel?
Yes, you can weld stainless steel to regular steel. However, I do not recommended it.
Stainless Steel is a heat-tolerant alloy that is made with chromium and other elements, which helps make it resistant to rust and corrosion.
It also has a higher melting point than regular steel. Because of these properties, stainless steel is often used in applications that involve high temperatures or exposure to water.
The issue with welding stainless steel to regular steel is that the two materials have different coefficient of expansion rates which can cause cracks in the weld area over time if it’s not done correctly.
Why is it Hard to Weld Stainless Steel?
Welding stainless steel is difficult because of the high melting point of the metal and its propensity to oxidize. In addition, there are certain types of stainless steel that are more difficult to weld than others.
It takes a lot of heat and time to melt stainless steel, so it can be tricky to get the right combination of both. This is especially true if you’re trying to weld something that is already hot.
If it’s already glowing red-hot, you might run into trouble when trying to start your welding process unless you have a way to keep the metal cool enough for the start of your weld.
Stainless Steel will also oxidize quickly if left exposed to oxygen after being heated for too long or at too high a temperature.
This makes it harder for the two pieces to be joined together during welding because they won’t stick together properly if there’s an oxide layer between them that prevents adhesion from happening properly during the cooling down period afterward—which can take several hours, depending on the thicknesses involved here!
Which Welding Rod is Effective for Welding Stainless Steel to Carbon Steel?
309 L is low-carbon stainless steel, which means it has less than 0.08% carbon. The rest of its composition is made up of chromium, nickel, manganese, and molybdenum. It has great corrosion resistance and can be used in a wide variety of environments.
It also has a high tensile strength, which means it is strong enough to withstand forces that might cause other materials to break or bend. 309 L can be used for welding and in situations where there are high temperatures involved.
309 L is an austenitic chromium alloy, so it contains more chromium than other types of stainless steel.
This makes it easier to weld; however, it does not have as much nickel as other types of stainless steel do, which means it will be more susceptible to corrosion if exposed to moisture or air at high temperatures for long periods of time (over 30 minutes).
So, I advise you to use a 309 L for welding stainless steel to carbon steel.
What are the Different Categories of Stainless Steel?
Stainless Steel is a type of metal that is rust-resistant, durable, and corrosion-free. It doesn’t get discolored or rusted easily, which makes it ideal for many applications.
Stainless Steel can be divided into three categories: austenitic, ferritic, and martensitic. Each type of stainless steel has unique properties that make it preferable for certain applications.
1. Austenitic Stainless Steel:
The most common type is austenitic stainless steel. The “A” in “AISI 304” (or other numbers) refers to the type of stainless steel. Austenitic stainless steels are non-magnetic, which makes them good choices for magnetic-based machinery or devices like MRI machines.
These types of stainless steel are also more resistant to corrosion than other types because they contain low levels of carbon and chromium.
2. Ferritic Stainless Steel:
Ferritic stainless steels are magnetic and have higher levels of carbon than austenitic do (up to 2%).
They have lower chromium content than austenitic do as well (16% max). Ferritic stainless steels can be used in many different applications; however, they tend to be less strong than martensitic or duplex versions of these metals because their crystal structure is not as dense as those others’.
3. Martensitic Stainless Steel:
Martensitic stainless steel is a type of stainless steel that has been used for decades by many industries.
It is known for its hardness, strength, and durability. Martensite is formed when austenite gets transformed into a different crystal structure at a higher temperature than what would be needed to form austenite from iron alone.
The resulting martensite structure is more stable than the austenite structure because it has more carbon atoms in it, and the carbon atoms are arranged in a more ordered pattern than they are in the iron-only crystal lattice.
This makes martensitic stainless steel resistant to corrosion and wear.
Martensitic stainless steel is used in a wide range of applications, including:
- Ball bearings
- Surgical instruments
- Valves
- Pumps for water treatment plants
- Used in automotive and aerospace applications
What are the Different Categories of Carbon Steel?
Carbon steel is made from iron and carbon, so it’s a very strong material. It has a wide variety of uses, and it can be used to make anything from pots and pans to knives.
There are many types of carbon steel. Below is a list of the most common types:
High carbon steel: High carbon steel has a carbon content of 0.05 to 0.30 % and is used for making high-strength products like axles, gears, bolts, and springs because it is relatively soft and easy to form.
Medium carbon steel: Medium carbon steel contains 0.30% to 0.50% carbon.. It is used in springs, fasteners, and other applications where strength is needed but not as much as high-carbon steel can provide.
Low-carbon Steel: Low-carbon Steel has a carbon content between 0.50 to 0.90%. It can be hardened by cold working to become case hardened or tempered to become spring tempered (hardened but able to bend).
Is it Possible to Weld Stainless Steel to Carbon Steel through TIG Welding?
You can TIG weld stainless to steel, but I do not consider it as a great idea.
TIG welding is a type of arc welding that uses a non-consumable electrode and inert gas, typically argon or helium.
It’s used primarily for welding thin metals like sheet metal and thin wire, but it can also be used to weld thicker materials like stainless steel if you use the right filler rod.
The problem with TIG welding stainless is that the current travels through the electrode and then heats up the filler material before it gets to your project.
This means that you have to use a special type of filler rod called nickel-chromium or nickel steel alloy—otherwise, the heat from the arc will melt your material before it reaches its melting point.
The other issue is that this kind of filler rod only works well on stainless steel when it’s less than 1/16″ thick; anything thicker than that, and you’ll get inconsistent results.
Limitations:
| No. | Limitations | Description |
| 1 | Expensive | The disadvantages of welding stainless Steel to carbon steel through TIG welding are that it is expensive, difficult to do, and does not produce a strong bond. |
| 2 | Difficult | It is much more difficult to achieve a good weld bead on stainless Steel than on carbon steel. This is due to the fact that stainless Steel has a higher thermal conductivity, which makes it harder to heat up and cool down quickly. |
| 3 | Weld Puddle Issues | Stainless Steel has a lower melting point than carbon steel; therefore, it can be more difficult to keep your weld puddle hot enough during welding. |
| 4 | Need for Special Equipment | You will need specialized equipment (such as stainless steel electrodes) for working with stainless Steel rather than ordinary carbon steel electrodes. |
Is it Possible to Weld Stainless Steel to Carbon Steel through MIG Welding?
Yes, you can MIG weld stainless steel to regular steel. However, the process is not as simple as welding two pieces of regular steel together.
The main challenge in welding stainless steel to regular steel is that stainless steel has a lower melting temperature than regular steel.
This means that if you try to weld it with a standard MIG welding machine, your arc won’t be hot enough to melt the base material before it burns out. You’ll also have trouble keeping your arc hot enough to melt through both materials at once.
I suggest you use a special MIG welder that can handle stainless steel—like the Millermatic® Auto-Set™ 200DX Millermatic® MIG Welder—or use a flux-cored wire made for stainless steel welding like Lincoln Electric’s PowerMelt® 400 Flux-Cored Wire.
These wires will produce an arc that’s hot enough to weld stainless metal without burning out or running into problems with melting temperatures (the higher the number on your flux-cored wire, the hotter it will run).
There are several disadvantages to welding stainless Steel to carbon steel through MIG welding, including:
| No. | Disadvantages |
| 1 | The most important thing anyone welding stainless steel needs to do is find a shielding gas that works well for this task. |
| 2 | The wire you use will cost more as well; stick rod spools cost about $50 for a range of sizes: .045″, .035″ & .025″, whereas MIG MIG wire spools come in packs of 100 feet costing $250+. |
| 3 | The spray mode works very well for thick metals, but you need a high amperage welding machine to ensure the wire feed rate is high enough. |
| 4 | You may need a wire feeder or spool gun to achieve a perfect job. |
Which Settings do you Need to MIG Weld Stainless Steel to Carbon Steel?
When you’re welding stainless steel, I recommend that you need to use the right settings.
Stainless Steel is a very common material to work with when you’re welding, and it’s important to know how to keep your welds strong. If you don’t use the right settings, your welds will be weak and brittle.
The most common way that people mess up their welds is by using too much heat. This causes the metal to become brittle and break apart when it’s bent or stressed after being cooled down.
You also need to control how much penetration your weld has so that it can hold up under high pressure without breaking apart or cracking.
To prevent these problems, you should use a lower voltage setting than normal when welding stainless steel with carbon steel.
This will help keep your welds strong enough for most applications while still allowing them to cool down quickly enough so they won’t crack or break apart later on down the line when they’re used under stress while being bent or twisted back into shape again.
Why is it Better to Avoid Welding Stainless Steel to Carbon Steel?
1. Difficult to Weld:
Welding stainless steel with carbon steel is a difficult process and even more difficult to do well.
Because of the difference in their chemical makeup, the two metals have different melting points. If the weld is not made at the right temperature, it can become brittle and crack.
Additionally, stainless steel has a lower yield strength than carbon steel, meaning it is less likely to bend or deform when pushed beyond its limits.
This makes welding very difficult because you must be careful not to put too much pressure on your workpiece while welding it.
2. Hot Cracking Issues:
There are a number of reasons why it is better to avoid welding stainless steel to carbon steel, but the most important is hot cracking, which occurs when the heat generated during welding causes a crack to form in the weld.
This can result in a weak spot that could potentially cause the welded area to fail.
The most common way to avoid hot cracking issues is by using filler materials such as stainless steel wire or rods that have a lower melting point than the base metal.
This will prevent the heat from reaching the base metal and causing cracks to form in the welded area.
This can be done by using filler materials that have a lower melting point than carbon steel or by adding extra layers of filler material onto your workpiece before welding it together with carbon steel.
3. Thermal Expansion Problems:
When welding stainless steel to carbon steel, you have to be aware of the thermal expansion problems.
Stainless Steel has a higher thermal expansion coefficient than carbon steel, which means that it expands and contracts more than carbon steel at different temperatures.
When you weld stainless steel to carbon steel, the stainless steel will expand more than the carbon steel due to its higher thermal expansion coefficient. This can cause stress fractures in your parts, which may lead to failure in service.
If you want to avoid this problem, then I suggest is by preheating your parts before welding them together.
Preheating causes both types of metal to expand at the same rate and keeps them from expanding too much when they are heated during the welding process.
4. Weaker Welds:
Welding stainless steel with carbon steel is a bad idea. For one thing, it’s not as strong as you might think. In fact, the welds are weaker than they would be if you were welding two pieces of stainless steel together.
The reason for this is that when you weld two pieces of carbon steel together, they fuse into one seamless piece of metal.
That’s because carbon steel melts at a lower temperature than stainless steel does, so the molten metal stays together longer before cooling down and forming an indentation in the surface of the metal that can weaken the weld.
The weld itself also tends to be less strong than other types of welds because it has more porosity (holes) in it due to its low melting point.
And although porosity isn’t always bad (it can actually help strengthen some materials) when it comes to welding stainless steel to carbon steel, it means your welds will have less strength overall than they would if they were made with different metals or different techniques such as TIG or MIG welding instead.
5. Corrosion Issues:
Welding stainless steel to carbon steel can create a number of problems, including corrosion. This is because of the different types of metals used in the welds and how they interact with each other.
Carbon steel is a ferrous alloy that contains between 0% and 2% of carbon. The carbon content gives it high strength and hardness, which makes it an excellent choice for many applications. However, it also has poor corrosion resistance compared to other metals like stainless steel.
Stainless Steel is an alloy that contains at least 10% chromium in order to be considered as such. It has good corrosion resistance, making it an ideal choice for outdoor applications where there is a lot of exposure to water or salt water (such as boats).
When you’re welding stainless steel and carbon steel together, the result is often a weld joint that has both good corrosion resistance and poor strength due to its composition being made up of varying amounts of ferrous and nonferrous metals.
Can you Weld Carbon Steel to Stainless Steel?
Yes, you can weld carbon steel to stainless steel, but the process is not as simple as welding two pieces of carbon steel together.
First of all, you need to use a filler rod that will be compatible with both types of metal. If the filler rod is too hard or soft, it will either crack or bend when you try to weld them together.
Secondly, you need to set up your welding machine so that it will allow you to get the right heat setting for both types of metal.
If one side gets too hot while welding and the other side doesn’t get hot enough, then your weld will break at some point during the process or after it has been completed.
Final Verdict!
This article offers clear and helpful tips about whether can you weld stainless steel to carbon steel. Now you know to clean both metals thoroughly and pick the process that is right for your project.
You know about the base metal, and you have a professional-grade welding technique to apply to your work.
FAQs:
Does stainless steel react with carbon?
Stainless Steel is a non-magnetic and corrosion-resistant metal. Carbon steel, on the other hand, is magnetic and reacts with oxygen to form rust. These two metals are not compatible with each other; if they come into contact with each other, the corrosion-resistant properties of stainless steel will absorb carbon from the rusting (carbon steel).
What welding rod do I use to weld stainless to carbon steel?
The most common metal that is welded together when working with stainless steel and carbon steel is 310L-16 stainless steel. The most popular welding rods that weld stainless to carbon are ER80S-6 for 1/16″, ER70S-6 for 3/32″, and ER70S-2 for 1/8″, but any Grade 416 rod could be used.
