Carbon steel and stainless steel are two of the most commonly used metals in manufacturing. They are also two of the more difficult metals to weld. When welding carbon steel or stainless steel, care must be taken to ensure that the joint is not compromised by embrittlement or stress corrosion cracking (SCC). If you are looking to weld these metals, read on as we explain the differences between carbon steel and stainless steel; the different types of welding equipment available. and tips for successful joint welding.
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Definition of carbon steel and what is stainless steel
Carbon steel is a type of iron-based metal that is recognizable by its high carbon content. High carbon steels are used most commonly in construction and mechanical industries, where they are exposed to regular wear and tear, and exposed to heat, fire, and chemicals. Stainless steel is a type of steel that contains at least 10.5% chromium, which is the chemical element making up stainless steel’s shiny, corrosion resistant surface. Stainless steel is sometimes confused with its low alloy counterpart, carbon steel. These two metals are distinct in numerous ways.
Differences between Welding Carbon Steel and Stainless Steel
There are some differences between carbon steel and stainless steel:
- Carbon steel is porous and stainless steel is not.
- Stainless steel is resistant to corrosion and carbon steel is not.
- Carbon steel is malleable and stainless steel is not.
- Carbon steel has a low melting point and stainless steel’s melting point is very high.
- Stainless steel is expensive and carbon steel is not.
Types of welders for welding carbon steel to stainless steel
Arc welding – The arc produced when welding carbon steel to stainless steel produces heat that melts the metal. This is the most common welding technique for carbon steel to stainless steel.
Gas tungsten arc welding (GTAW) – GTAW uses a high-frequency energy source to create a plasma arc. The plasma arc melts the metal, while the filler metal welds the two pieces together. GTAW is a welding process used to weld carbon steel to stainless steel.
Flux cored arc welding (FCAW) – FCAW uses a pure metal welding process to weld carbon steel to stainless steel. It’s a pure metal welding process that doesn’t require the use of a flux.
Welding carbon steel to stainless steel
Carbon steel is welded to stainless steel to create a welded stainless steel. Welding carbon steel to stainless steel is an effective way to join two types of steels. However, like all welding, it must be done correctly, using the right equipment, and in the right environment. The welded stainless steel joint is very strong. It’s non-toxic and it can be used outdoors without corrosion.
Successful welding for carbon steel to stainless steel
Proper joint preparation for welding carbon steel to stainless steel is crucial for ensuring that the joint does not become contaminated with carbon steel. The contamination can cause the joint to become brittle and lead to stress corrosion cracking of the stainless steel. To prevent contamination, ensure that both parts of the joint have been cleaned and dry. When welding, heat both parts of the joint evenly and ensure that the torch is touching the joint, not the wall. Weld the joint until it is at the correct temperature. Ensure that there are no sparks flying out of the torch.
Tips for successful joint welding between carbon steel and stainless steel
- Ensure clean, dry parts – When welding between two parts, ensure parts are clean and dry. Clean parts will help to prevent contamination.
- Ensure joint is evenly heated – When welding between two parts, ensure that the joint is heated evenly through the joint.
- Ensure torch is touching joint, not the wall – When welding between two parts, ensure that the torch is touching the joint, not the wall.
- Weld the joint until it is at the correct temperature – When welding between two parts, ensure that the weld is at the correct temperature.
- Use shielding gas – When welding between two parts, use shielding gas when welding between two parts.
- Wear safety glasses – When welding between parts, ensure that both parts are wearing safety glasses.
- Wear gloves – When welding between parts, ensure that both parts are wearing gloves.
- Wear breathing equipment – When welding between parts, ensure that both parts are wearing breathing equipment.
- Wear hearing protection – When welding between parts, ensure that both parts are wearing hearing protection.
- Don’t overheat – When welding between parts, don’t overheat the joint.
Last word about Welding of carbon steel to stainless steel
Welding carbon steel to stainless steel is a challenging task. These two types of steel have very different characteristics. If you’re looking to weld steel, read on as we explain the differences between carbon steel and stainless steel; the different types of welders available; and tips for successful joint welding.
