4 Types of Metal Used in Welding Projects

Welding is one of the most durable ways to connect pieces of metal. It's used for everything from car parts to fences to building structures. While most metals do best when welded to similar materials, welding of dissimilar metals is also possible in some cases, depending on the makeup of the metals and the welding process used to fuse them. To better understand the process and the variety of constructions possible through welding, learn more about several metals that are commonly used in welding projects. 1. Aluminum As the most abundant metal on earth, aluminum is used in a variety of applications. Aluminum has an unusually great ability to resist corrosion, which makes it durable and less prone to damage over time. The material is used in a wide variety of industries, many of which require welding for certain materials. You can find aluminum in all sorts of vehicles, from cars to airplanes. It's also used in buildings, especially in places where its lightweight and durable features are prioritized. Aluminum welding works best with stick welding, gas metal arc welding, and AC-TIG welding. Not all aluminum can be easily welded, however. Certain grades of aluminum weld more easily than others. Some require extra care, including filler materials that help the materials fuse together. 2. Steel Perhaps the most common metal used in welding projects, steel has many qualities that make it ideal for this process. Steel is relatively cheap, which makes it a popular choice. It also has a high tensile strength, which means that it can withstand a great deal of stress before it breaks. As an alloy, steel comes in several different forms. Welders use stainless steel, carbon steel, and low-carbon mild steel, depending on the project. Mild steel is especially ductile, which makes it easy to weld. The more carbon steel has, the more effort it takes to weld, though welding carbon steels still happens with the proper equipment and methods. Like aluminum, steel is common in transportation vehicles of all types. Because it's strong and cheap, it is also used in a variety of buildings and architecture. It's also commonly used in weapons and appliances. Steel welding works with most welding types, which is another reason it's a popular material. Methods used for steel welding include stick welding, flux wire welding, gas metal arc welding, resistance spot welding, and DC-TIG welding. AC-TIG welding is not typically used with steel parts. 3. Cast Iron Cast iron is, as expected, a type of iron. Often, the term cast refers to materials that have been shaped for a particular purpose. As a material, cast iron has a relatively low melting point, which makes it a great candidate for welding. Cast iron has been famously used in bridges throughout history. It's also commonly used in fences and ornamental pieces like statues. In smaller projects, it's a common material for kitchen appliances such as pans and waffle irons. You can also find pipes made of the material. Cast iron responds best to traditional stick welding. Because of its low melting point, more specialized methods of welding are typically unnecessary. 4. Other Metals Many other materials are routinely used in welding projects. Magnesium alloys, brass, copper, and titanium are common. Unlike aluminum, steel, and iron, which can all be welded using basic stick welding, these metals require more specialized methods. Magnesium alloys can be welded with AC-TIG welding methods. Brass and copper respond best to DC-TIG welding, as does titanium. These methods require specialized equipment and safety measures, so only qualified, experienced welders should handle them. Which metal you use depends on the project and what welding methods are available. At Sam's Welding, Inc, we offer both in-shop and mobile welding services. Contact us today to make a plan for your welding project.