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Weldability is everything. Metals with a high weldability are easier to weld and retain a higher weld quality than other metals, so it’s important to study these factors before choosing materials for a project.
Once you’ve narrowed down your selection to a few metals, the next step is to determine which welding process you’d like to use. Some methods require more skill than others, such as TIG welding — and these will affect which metals are at your disposal. For example, the ideal metals for MIG welding are carbon steel, stainless steel, and aluminum, all for different reasons.
The main parameters that determine a metal’s weldability include the electrode material, cooling rate, shielding gases, and welding speed. Every metal is unique. To a certain extent, all metals can be welded, but there are clear advantages and disadvantages to each.
Stick welding, also known as shielded metal arc welding (SMAW), is one of the most common welding methods out there. To get started, you’ll need a welding machine, a proper electrode (we recommend DCEP for DC welding), a safety helmet, clamps to hold the joints together, and your welding metal of choice. With this method, you are melting a metal rod with a special flux coating that prevents oxygen contamination — hence the “shielded metal” name. Stick welding can be used to weld steel, iron, aluminum, copper, and nickel.
Unlike stick welding, gas metal arc welding (or GMAW) does not have a coating over the electrode rod. Instead, the welding gun disperses a shielding gas that protects against contaminants. It’s the most common industrial welding process today, and can be used for steel, cast iron, magnesium, and many other metals.
Ultimately, there is no clear-cut answer when deciding which metals and welding methods to use. It’s best to figure out which metals are best suited (and most cost-effective) for your project, and then decide on a welding style that can be performed with your skill set.