Posted by admin on Friday, November 7, 2008 · Leave a Comment
Almost *all* metals can be MIG welded- carbon steel, stainless, aluminum, cast iron, copper alloys, nickel alloys, even magnesium. MIG is generally the most useful, fastest, and most cost effective process.
The only exception that I know of is Titanium, which is very sensitive to contamination. Ti requires the very "clean" welds produced by TIG welding, no other process will produce acceptable Ti welds. Also, some extreme service alloys such as "Inconel" may benefit from the cleanliness of TIG welds.
TIG can weld ALL metals, however TIG is a very slow process, and it requires welders with a much training and experience. Therefore, it is by far the most expensive and labor-intensive process. TIG tends to produce more heat input than other processes which increases the potential for warping, and may be detrimental to some materials, i.e. those prone to hot cracking. Also the more difficult the welding process is, the greater the risk of human errors.
TIG is generally NOT cost effective for production welding, unless very clean, spatter-free, cosmetic-looking welds are needed.
Carbon steel, cast iron, nickel alloys, and to a certain extent stainless steel can be stick welded. Electrodes do exist that are designed for stick welding aluminum. However I consider these inferior products and they should not be used by serious welders.
Stick welding should be considered an almost obsolete process. It does have some use for welding in the field, when other processes simply could not be used. In practice such situations are rare. Stick welding is slow, primitive, difficult, is limited to thicker materials, and it produces welds with more defects than other processes.
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