Welding stainless to mild steel: Step by Step Procedure

Welding stainless to mild steel can be done using Stick Welding, TIG Welding, MIG welding and FCAW welding process. Brazing can also be used to weld stainless steel to mild steel.

This post explains step by step procedure for welding stainless to mild steel using TIG, Stick, MIG and FCAW Welding.

The most common welding method is to use a stick welder with a stainless steel electrode to weld stainless steel to mild steel.

This method is best for welding thin sheets of stainless steel to mild steel. Another method that can be used is gas tungsten arc welding, which is best for welding thicker pieces of stainless steel to mild steel.

Can you weld stainless to mild steel?

The quick answer is yes, you can weld stainless steel to mild steel. This is typically done using a stick welder or TIG welder or mig welder.

Welding stainless steel to mild steel

The process is fairly simple and doesn’t require any special tools or knowledge. However, there are a few things to keep in mind when welding these two metals together.

  • First, it’s important to use the right type of filler rod. For welding stainless steel to mild steel, you’ll want to use a 309L/ ER309L filler rod.
  • This type of filler rod is specifically designed for joining dissimilar metals and will help to prevent corrosion.

  • Second, you’ll need to pay attention to your welding technique. When welding stainless steel, it’s important to use short, quick strokes.
  • This helps to prevent the formation of hot spots, which can lead to warping or cracking.
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  • Third, stainless steel has a higher melting point than mild steel. This means that it will take longer to heat up and will require more energy to weld.

Welding Rods for Welding stainless steel to mild steel

Welding rods/ filler wires for welding stainless to mild steel using Stick Welding, TIG welding, MIG welding, Flux core welding and metal core welding are given in the below table.

E309L-16 Stick Welding Rod

Welding stainless steel to mild steel by Stick Welding

One of the most common questions we get asked is “can I weld stainless steel to mild steel?”

The answer is yes! Welding stainless to mild steel is widely carried out using a stick welder.

Before you start Welding:

5-Easy Steps for Welding stainless steel to mild steel by Stick Welding

  1. Preclean the parts to be welded. Make sure they are free from rust, oil, grease or moisture.
  2. Make sure to use a properly baked welding rod if not using a hermetically sealed pack rod. Moisture in the rod results in welding porosity.
  3. Use all required PPE (gloves, welding helmet, boot, etc.).
  4. For welding stainless steel to mild steel, you can use an E309L rod or ENiFeCr-3 (Costly rod). E309L is cheap but can be used up to 600 Deg F.
  5. Make note that You don’t need any gas purging or shielding when welding stainless with stick welding.  
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Welding stainless to mild steel by TIG Welding

TIG welding is the best way to weld these two metals together. It uses a non-consumable tungsten electrode to create the arc.

This method is preferred because it allows for more control over the weld pool.

Before you start Welding:

7-Steps for welding stainless to mild steel with TIG Welding

Read More: Curious about shielding gas, purging & trailing gas? Know the answers!

  1. Wear your safety gear.
  2. Preclean the parts before welding.
  3. Carry out the tacking of parts using ER309L TIG filler wire rod.
  4. No preheating is required for mild steel & stainless steel (for austenitic stainless steel).
  5. If welding open root, apply gas purging to avoid oxidation.
  6. Carry out full welding using ER309L welding rod.
  7. Grind any uneven bead if required.

Welding stainless to mild steel by MIG Welding

MIG Welding is a great way to weld stainless to mild steel. To have a good quality weld, First, you need to use the right type of wire.

Welding Shielding Gases: Which One is Right For You?

Second, you need to set your welder to the proper settings. Third, you need to use the correct welding technique.

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Fourth, you should practice on some scrap pieces before welding your project.

Before you start, make sure to have:

Steps for welding stainless steel to mild steel with MIG Welding

  • Wear your safety gear.
  • Setup the MIG welder. Check for the supply of welding gas to torch.
  • Make a trial run on scrap metal.
  • Set the gas flow to 20- 30 CFH. Apply gas purging if required.
  • Set the welding ampere around 120- 150 for open root and 200 amps for welding on thicker plates to weld filet & fill passes.
  • Carry out the welding using ER309L welding wire.
  • Clean the weld using a wire brush/ grinder as required.

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