What Are the Easiest Metals to Weld?

Welding can be challenging, and the science behind it can strike a difficult balance. Still, with the right methods and the proper training, welding offers a permanent and secure connection between two workpieces. Metals can come in various sizes and densities, each with an optimal welding method. The two main methods are TIG and MIG. Your industry or equipment will determine which method you will most commonly use.

Of course, your preferred method could depend on the regular use of the type of metal you will be welding. Each metal will come with its own pros and cons, and as bottled gas suppliers, we will ensure to cover the difficulties of each metal, advising which is easiest for entry-level welding. If you are looking for more tips on beginning a career or project with welding, we also have a helpful guide for beginners with more information about having the correct tools and equipment.

Mild Steel

Mild steel is a metal which contains low amounts of carbon and is predominantly made up of iron. Low carbon levels provide the metal with more ductile and machinable properties, and it is the most commonly used metal in construction and manufacturing. It is used for structural steel, signs, automobiles, furniture, etc. One of the reasons it is used for a lot of manufacturing is due to its ease when it comes to welding. It can be welded with both MIG and TIG methods and is one of the more versatile metals in welding. However, you must ensure to use the corresponding gas, and if you are unsure about which MIG or TIG welding gas you require, our knowledgeable staff can always help.

Stainless Steel

304-grade stainless steel is very easy to weld but can warp if too much heat is applied, which is why this metal may be more difficult for an entry-level welder. The best welding method for this metal is MIG and using the right amount of welding gas can help, and practice makes perfect. Stainless steel, much like mild steel, is a very versatile metal used worldwide.

Its resistance to corrosion offers a sterile solution for pharmaceutical and scientific solutions, whilst its heat resistance provides an excellent use in the hospitality and food sector.

Nickel

Remarkably similar to mild steel, this metal is easy to weld using MIG or TIG welding methods. Although its ease of application within the welding process makes it ideal for entry-level welders, the metal does not produce the strongest hold. It is susceptible to porous materials, which will make the metal joins give over time.

Aluminium

When it comes to welding aluminium, it offers good strength-to-weight ratios at low-cost solutions. Therefore it is an excellent metal for manufacturing and construction. You can use MIG or TIG welding methods for this particular metal, and if you take the time to learn about the metal and the process, it can be a reasonably easy metal to work with. Aluminium also requires a lot of specific equipment, including drive roll. When applying the MIG welding method, you will need aluminium MIG wire and good quality MIG welding gas.

Bronze

When welding bronze, it is recommended that you use the MIG welding method. It is mainly used for medals and musical instruments but is also used to produce bushes and bearings for industrial applications. It isn’t an easy metal to bond with a weld and may require some experience due to needing a hotter weld. It takes a lot of continuous heat to ply the join together, which can overload your machines and be a somewhat challenging process.

Copper

Unlike the metals above, copper requires soldering or brazing for the perfect finish. Much like bronze, the MIG method is the most appropriate when welding. The most common use of copper is within electrical wiring due to its excellent conductive properties, and its malleability makes brilliant material for copper piping. Although the difficulty of this metal is not challenging, it does require a confident knowledge of the process and knowing when soldering would be a more suitable join.

Cast Iron

Cast iron is one of the more difficult metals to weld due to its brittle nature. Heating or cooling cast iron too quickly can result in cracking later on and can compromise your weld. Stick welding is often the safest option when working with this material, and the difficulty lies in understanding the welding process. Despite being a complex metal to weld, repairing cast iron welds is not too complicated and, with experience, can become a relatively uncomplicated process.

Galvanised Metal

Zinc is used to help reinforce this metal, and when welding can lead to many health hazards. Working with galvanised metal is not only a problematic weld but can be dangerous due to the zinc coating. It requires vital protective equipment, and the zinc can interfere with the weld, which often is not caught until the job is finished. The reinforcement layer also makes it more challenging to penetrate the material. If you are going to weld galvanised metal, it is advised that MIG is used as a welding method.

Working With Other Metals

Of course, depending on your field of work or project, there could be many other metals that will require welding. For the likes of titanium and brass, once you have learnt its properties and the best way to conduct a weld, it can become second nature. This is recommended for any welding process, understanding your equipment and material to ensure the best finish and a reliable join.

Using a responsible and expert company is always the best solution for all your welding equipment and needs. We have a range of welding products online to browse through, including all the welding gases you require for various metals. If you ever need advice on the best gas for your particular application, you can contact us; our staff are happy to help.