Learn 5 Best Practices, Including Pulsed MIG, for Welding Different Materials

Welding aluminum, stainless and more

Carbon steel base materials are often used in many welding applications, offering easy weldability and affordability. But aluminum and stainless steel — and even materials like titanium and silicon bronze — are becoming more common in fabricating and manufacturing for many reasons.

Welding many types of materials can require an investment in more welding equipment. It also often takes more time for setup and changeover between applications.

As more manufacturers and contractors are faced with the challenges of welding a wider range of materials, they want solutions that help save time and money. There are welding technologies and processes that make it easier and more efficient for operations to produce high-quality welds — no matter the material being welded.

Welding different materials

The material evolution in the manufacturing industry stems from several factors. In some industries, there is a push toward lighter weight and corrosion resistant materials and components. This is driving the use of aluminum, high-strength steels and stainless steel. In addition, a growing manufacturing economy allows contractors and OEMs to take on more contracts — and wider variety of jobs. This increases the chance that companies will need to weld different materials beyond traditional carbon steel.

If an operation doesn’t have the right welding equipment, the need to weld different materials can present challenges. Some metals require different techniques or processes to achieve the best results. For operations welding only carbon steel, constant voltage (CV) MIG is often a good choice. Aluminum and stainless steel are better-suited for pulsed MIG welding.

These best practices will help you choose welding solutions specifically designed for different types of materials and gain flexibility and efficiency while producing high-quality welds on many metals.

Tip No. 1: Avoid the basic feeder option

When choosing a wire feeder for welding different materials, it pays to go beyond the basic option. Wire feeders with more advanced technologies can save time and improve productivity. This is especially true in welding operations that frequently switch back and forth between materials.

Some companies have separate welding cells for specific material types — one cell for welding aluminum and another for welding carbon steel, for example. Using a dual feeder system eliminates the need for separate welding cells by material type.

With a dual feeder solution, one side can be set up for aluminum and the other side can be set up for carbon steel or stainless steel. Welders can easily switch between sides — eliminating the need to change out filler metal every time the welded material changes. This option reduces the equipment investment and saves floor space. The same power source can be used with two feeders in the same weld cell, rather than outfitting two cells with more equipment.

An integrated system package that includes the power source and feeder on one MIG runner cart saves time in setup. It also frees up space on the welding floor and makes it easier to move equipment from one cell to another.

Filler metals used for soft alloys like aluminum, small-diameter stainless and silicon bronze can be more difficult to feed. It’s recommended to use a push-pull system for smoother wire feeding.

More advanced wire feeders let welders save different weld programs. The correct parameters for specific applications can be easily retrieved with the push of a button. This saves significant time in setup and changeover between material types.

Tip No. 2: Consider a switch to pulsed MIG welding

When an operation must frequently weld aluminum or stainless steels, choosing a feeder and power source with pulsed MIG capabilities can help welders produce high-quality welds and reduce rework.

While aluminum can be welded using a CV MIG process, pulsed welding is a much better option for the material. The process provides lower heat input and greater arc control — reducing spatter, porosity, and the risk of distortion and burn-through. This results in less rework and improved cycle times, so a company can get more parts out the door.

Beyond standard pulsed MIG, there are other advanced pulsed processes available that are designed to help welders produce a better bead profile and weld appearance. Advanced pulse arcs are typically smoother and more forgiving. They compensate for a lack of welder experience or consistency by bridging the gap between varying travel speeds and contact-tip-to-work distances. This makes it easier to consistently produce quality welds.

Tip No. 3: Look for easy-to-use technology

Setting the right welding parameters to ensure the proper bead profile and penetration can be more difficult with materials like aluminum and stainless steel. Look for welding technologies and equipment designed to make this easier.

Some welding power sources assist welders in setting proper parameters. The welder simply inputs the material type and thickness along with the wire type and size. The machine then sets the necessary parameters to produce a quality weld.

In addition, other technologies can provide benefits for specific materials. A power source with crater and hot start is helpful when welding aluminum, providing better arc starting and stopping capabilities. Typically, the start of the weld is very cold, which can result in cold lap on the first weld pass. A machine with hot start technology helps establish the arc and immediately provide good fusion. Crater technology helps prevent weld cracking by properly filling in the ends of the weld.

Tip No. 4: Select the right filler metals

Beyond choosing the right power source and feeder, it’s important to follow some best practices for material storage and welding.

Selecting the right filler metal for the application and base material is critical. There are many different types of aluminum and stainless steels, so be sure to match the filler metal to the mechanical and chemical properties of the base metal.

Proper storage is especially critical for aluminum. When aluminum is exposed to moisture and not allowed to dry — or the oxide isn’t removed — it can result in hydrogen in the weld, causing porosity. Store aluminum in a clean, dry place, and properly clean your base material to remove all oxides before welding.

Tip No. 5: Use your consumables wisely

Do not use a liner and consumables to weld aluminum that were used to weld steel. This can result in cross-contamination or wire feeding issues. Carbon steel generally requires a steel liner, while aluminum uses a plastic or Teflon liner with tighter tolerances. You also need to use the correct drive rolls and feeding guides for the base material.

Successfully welding many materials

More manufacturers are tasked with welding many different types of materials. There are welding technologies that can help. Advanced wire feeders and processes such as pulsed MIG are designed to save time in setup and help operators produce high-quality welds. Going beyond the basic options and investing in these added capabilities can have a big impact on the bottom line.