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The Most Common Welding Metals and When to Use Them.
Do you have a welding project in mind, but you aren’t sure what material to buy? Fortunately for you, we are here to explain the most common metals and when you should use each one. There are 3 main metals used in most welding projects. They are as follows:
1) Carbon Steel
2) Stainless Steel
3) Aluminum
So how do we choose which one to use? Well first we need to understand the important properties of each.[/et_pb_text][/et_pb_column][/et_pb_row][/et_pb_section][et_pb_section fb_built=”1″ _builder_version=”4.9.2″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_row _builder_version=”4.9.2″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_column type=”4_4″ _builder_version=”4.9.2″ _module_preset=”default” global_colors_info=”{}” theme_builder_area=”post_content”][et_pb_text _builder_version=”4.9.2″ _module_preset=”default” header_3_text_align=”center” custom_padding=”||1px|||” global_colors_info=”{}” theme_builder_area=”post_content”]
Understanding The Properties
There are 5 main traits we will focus on for these metals. They are defined below for you
Ductility – How much you can shape or bend the metal before it breaks
Strength – How much pressure or force can be exerted onto the metal
Melting Point – How much heat needs to be applied before it can be liquified
Weight – How heavy the metal is
Corrosion – How prone the metals are to rusting
These traits vary with each metal and should be determining factors when you are deciding between each metal. Now lets take a look at the metals!
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Carbon Steel
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Carbon Steel is a metal alloy composed primarily of iron, and up to 2% of carbon. Due to the variations of how much carbon is added, steel can have a wide range of ductility as well as strength. In short, the higher the strength of the steel, the lower the ductility, and vice versa. This is usually determined by how much carbon is used in the alloy.
High carbon steel is very strong, and great for structural applications, but is not very flexible. Low carbon steel on the hand, is much more flexible, and is more commonly used in automobile bodies, but lacks some of the strength of the higher carbon steel. Medium carbon steel lands right in between the two in terms of strength and ductility. Steel is rated as high carbon if it has between .55% all the way up to 2% carbon in its composition. Medium carbon is .25% to .55%, and low carbon steel is .25% carbon and under.
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Carbon steel is a very heavy metal, and weighs roughly 489 lbs. per cubic foot. This heavy weight is important to account for when using steel. One of the downsides to using Carbon steel, is that it is susceptible to corrosion. While it boasts higher tensile strength than its counterpart in stainless steel, carbon steel can quickly rust when exposed to too much moisture. In fact just the moisture in the air can be enough to lead to rust forming.
Carbon steel has a melting point between 2600-2800 F. This number varies based on how much carbon is in the steel, with higher levels of carbon leading to lower melting points. While this number may seem large, a temperature of over 2800F is easily achieved by any of the 4 most common welding styles. For more information about the 4 most common types of welding, check out our other blog post about the welding styles!
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Stainless Steel
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Stainless steel starts off with iron, the same way that carbon steel does, however it adds between 10-30% chromium. This chromium is important because unlike iron, chromium is resistant to oxidization. This oxidization is what leads to steel rusting and turning that brownish red color. Stainless steel lives up to its namesake because it simply does not rust the same way that normal steel does.
Stainless steel can be a very ductile metal, when compared to high carbon steel. It does however lack the same tensile strength that high carbon steel can have. Stainless steel is more commonly used in the restaurant and medical industries, as it is very easy to sanitize and clean. It does however weigh just about as much as carbon steel, coming in at 490 lbs. per cubic foot.
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Stainless steel has a melting point similar to carbon steel, melting at 2750F. This means that also like carbon steel, stainless steel can be used with any of the 4 most common types of welding. The biggest downside to using stainless steel, is its cost. Stainless steel is incredibly expensive when compared to regular steel, often costing as much as 5 times the price.
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Aluminum
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The final commonly used metal, is Aluminum. Aluminum has similar corrosion resistance to stainless steel. It is incredibly ductile, making it very versatile to use in product creation. The downside to aluminum, is its lack of tensile strength when compared the previous two metals. It is also incredibly lightweight when compared to the previous two metals, coming at almost one third the weight of them. Aluminum weighs roughly 168 lbs. per cubic foot.
The main advantages to aluminum are the low corrosion, combined with the lightweight properties, as well as the high levels of conductivity. This makes it an ideal metal to weld for electrical applications and machinery. The lightweight nature makes it highly portable and easy for mobile welding applications.
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Pure aluminum has a melting point of roughly 1220F, however aluminum alloys can melt at temperatures as low as 900F. This low temperature means it can be welded using any of the 4 popular techniques, as well as allows it to be used well as a filler metal. In terms of price point, aluminum is typically cheaper than stainless steel, but still more expensive than carbon steel.
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So Which Should You Use?
Well now you know the differences between them, and the recomended applications for each metal. Of course, there are other metals you can use, and depending on the application, we may even recommend a specific one. Lucky for you, we are here to help you decide which metal to use and when. We offer welding consultations and mobile welding services throughout all of Southern California. Feel free to fill out the consulation form below to schedule your consulation!
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Get In Touch
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4 Reasons You Should Hire A Mobile Welder
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So you found yourself in need of welding services. Now you have to make the decision, do I take the project to a weld shop, or do I hire a mobile welder to come to me?
This is a common question asked by our customers looking for the right welding services for them. Fortunately for you, there are plenty of reasons why a mobile welder could be the right fit for you. For now, we will start with just 4.
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1) Convenience
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Let’s start with the obvious, we come to you. Not only does this save you the commute, but when it comes to bigger projects, moving the project may not always be possible. You shouldn’t have to dismantle your home gate just to have a new lock added on. Fortunately for you, our mobile welding team will come to you and save you the hassle of bringing the project to us.
Not only do we save you the hassle of dismantling your project, but we can also make an easier assessment of your project needs by seeing the whole scope of the project in one convenient place.
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2) Schedule Flexibility
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You make the appointments around your hours and that’s when we do the job. We show up where and when you tell us to so we can get the job done on your time. Many welding shops have limited hours of availability that you may not be able to work around. Our mobile welding teams on the other hand, are much more flexible and able to work around your scheduling needs!
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3) Speed & Efficiency:
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If you take your project to a work shop the chances are, you are not the only one there. There could be other projects being worked on by their welding team that take priority over yours. If your project is time sensitive, taking it to a welding shop may cause you to miss your deadlines.
When our mobile team comes to you, rest assured that your project is the only one we are focused on, and we will work to finish the project efficiently and to the highest standard.
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4) Personalization:
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Not only do we come to you and your project, but we tailor ours services based on your needs. Whether you are looking for us to weld a specific type of metal, or a specific welding technique, our team has the experience and credentials to provide you with the services you need. We will take stock of the project and help choose the right welding technique for your project. Additionally, when our mobile welders are working on your project on-site we can make adjustments based on your needs. Our professional welders will finish the project according to your specifications and needs.
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When you find yourself in need of welding services, you may have to decide between a mobile welder or a welding shop. Fortunately for you, we can help make the decision easy for you. For more information about how our mobile welding team can help you, check out our services page to set up a consultation!
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What are the 4 most common welding processes?
When looking into welding services, there is a wide variety of techniques available. These techniques range from gas welding to plasma welding, however 4 techniques stand out as the most common. These techniques are:
- MIG – Metal Inert Gas Welding
- TIG – Tungsten Inert Gas Welding
- SMAW – Shielded Metal Arc Welding
- Oxy-Acetylene Welding
Each of these processes offer their own unique advantages and disadvantages and are ideal for specific applications. Fortunately for you, our experts at California On-Site Welding are here to explain when and why they are used.
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MIG – Metal Inert Gas Welding
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MIG welding, often called wire welding, is a process that continuously feeds an electrode current through a thin wire. This current creates an electric arc when it comes in contact with the metal it is welding that heats up rapidly. Once the metal reaches its melting point, it can be joined together with another metal, along with the wire rod that serves as a filler metal. The efficiency of the electrode makes this welding process a great choice when you need a welding service with minimal cleanup that creates very strong welds.
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Of course, there are also disadvantages to using MIG welding. The first is that it requires a shielding gas. This gas is used to prevent the base material from being exposed to chemicals within the atmosphere that could potentially lead to holes within the weld. While this gas serves the purpose well, it makes it difficult to use this welding process in a windy environment. The weld created by this process, while very strong, is ineffective when it comes to welding thicker pieces of metal.
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The advantages of MIG welding are numerous as well. First, the process is very versatile and can be used in a lot of applications. In fact MIG welding is capable of being used on almost every metal. MIG welding is also one of the fastest types of welding that does not sacrifice the quality of the weld. Some of the more common applications for MIG welding are: pipe repair, automative repair, sheet welding and more.
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TIG – Tungsten Inert Gas Welding
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TIG Welding is very similar to MIG welding. Both types of welding rely on an electrode current being run through a conductor, in this case tungsten. This electrode then creates an electrode arc with the base metal and rapidly heats up. Unlike in MIG welding, TIG welding requires a hand held welding rod to serve as a filler metal. The tungsten rod produces a small, but very strong electrode arc making it ideal for precision welds.
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The disadvantage to TIG welding is similar to that of MIG welding, the requirement of shielding gas. This shielding gas makes it hard to use in outdoor situations where it may be too windy. It is also more difficult to use, given the high precision of the electrode arc.
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There are multiple advantages to using TIG welding. First and foremost, the precision allows for a very clean weld with a high degree of purity. The welds made through this technique are highly aesthetic, and it can be used with very thin metals. Some of the more common applications of TIG welding include bike repair, vehicle repair, and machine repair.
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SMAW – Shielded Metal Arc Welding
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SMAW welding, also referred to as stick welding, is another type of electrode welding. In this process, an electrode current is ran through a metal wire rod with an exterior flux coating. As the electric arc heats up, the flux coating melts creating a gas shield, similar to the gas shields being used in the previous techniques without the need of an external gas tank. The wire metal melts as well and is used as the filler metal to weld the base metals together.
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The disadvantages of SMAW welding, compared to the previous two, is the quality of the weld. The weld is is generally not as strong as the MIG or TIG welding processes. SMAW welding also requires more cleanup than the previous techniques. It leaves a layer of slag on the welding metal, and needs to be removed once the process ends. This process is also slower than the previous two.
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The primary advantage of SMAW welding, is the lack of gas required. SMAW welding is easily portable, and can be used in a windy environment without the same issues that TIG and MIG run into. It is also able to be used at every angle, making it the best option for hard to reach places. Some of the more common applications for SMAW welding include maintenence and repair.
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Oxy-Acetylene Welding
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Oxy-Acetylene welding is our final welding technique, and the only one that does not feature an electrode arc. This technique features a flame created through a handheld torch. This flame is fueled by a combination of oxygen and acetylene, and can reach temperatures of up to 3200 degrees Fahrenheit. This temperature is hot enough to melt most commercial metals. As the base metal heats up, a filler rod is supplied by hand.
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Gas welding, just like SMAW welding, produces a layer of slag when used. This layer should be removed once the process is done. This type of welding also provides a less precise weld line and may not look as neat as the previous techniques. Oxy-Acetylene also creates large heat affected zones, so it may not be the right choice for repairing machinery that is heat sensitive.
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The advantages to Oxy-Acetylene welding come primarily from the high heat it is capable of reaching. This welding technique is able to melt virtually every commercial metal, and can be used in just about any welding situation. The flame can also be used to cut the metal. Some of the more common applications of Oxy-Acetylene welding are: shop fabrication, pipe repair, and joining high carbon steel.
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Deciding which technique to use can be difficult. Fortunately, California On-Site Welding is here to make it easy for you. Our team of experts has been providing expert craftsmanship to Southern California for over 25 years. We have the knowledge and experience to know which technique is right for any job. Contact us to learn more about how we can help you. For more information about the services we can provide for you, check out our services page!
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