Metal fabrication professionals use welding to create parts and finished products for a wide range of industries. Certain welding materials tend to form bonds more easily than others. The best metals for welding depend on the project in question and the technique used. This overview of the best welding materials will provide a brief explanation of each metal’s suitability.

Techniques for Welding With Different Metals

Welding involves multiple techniques suited to different applications and materials. The most common welding processes include:

  • Resistance welding
  • Shielded metal arc welding (SMAW)
  • Gas metal arc welding (MIG)
  • Gas tungsten arc welding (AC-TIG or DC-TIG)
  • Flux-cored arc welding (FCAW)

Each process has an approach suited to different types of metals. They each have a unique energy source that induces fusion between the base materials. Since every metal has various melting points and cell structures, they have better compatibility with some techniques than others.

Steel and Stainless Steel

Most suitable welding techniques: SMAW, DC-TIG, MIG, FCAW, resistance

Iron-based metals such as steel and stainless steel tend to work with the highest number of techniques compared to others. Low carbon mild steel acts as one of the most weldable metals available. Its composition includes low amounts of elements that can decrease the risk of a failed weld. Stainless steel has a more complex chemical composition, but it can also work with multiple techniques that account for oxidation.


Most suitable welding techniques: SMAW, AC-TIG, MIG

Grades of aluminum that fall in the 1XXX and 6XXX series can undergo select welding techniques. A 1XXX series aluminum does not require much extra effort during the welding process, making it simple to handle. Meanwhile, a welder can work with 6XXX aluminum if they use proper welding operations and filler material.


Most suitable welding technique: DC-TIG

When a welder protects titanium from oxidation, they can use it to achieve sturdy and long-lasting results. Titanium requires full coverage from a shielding gas to provide a high level of weld integrity.

Cast Iron

Most suitable welding technique: SMAW

Cast iron poses more difficulty during the welding process than metals such as steel or aluminum. Its high carbon content requires careful preheating and heating methods that provide gradual temperature changes.

Copper and Brass

Most suitable welding technique: DC-TIG

Copper and brass have high corrosion resistance that makes them useful for a variety of welding applications. During the welding process, the welder needs to account for any alloys in the material that cause cracks or oxidation.

Magnesium Alloy

Most suitable welding technique: AC-TIG

A magnesium alloy has similar properties to aluminum. The magnesium in the alloy has a much lower melting point than oxides, making it critical to remove oxides before welding.

Welding Services From Fairlawn Tool, Inc.

The welding process requires professional techniques and knowledge of weldable metals. Fairlawn Tool, Inc. provides robotic and manual welding services as part of our single-source metal fabrication solutions. Our team utilizes MIG, TIG and spot welding to work with a variety of metals. For more information about the materials we handle and our welding services, contact us online today.

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