Stainless steel is one of the most versatile and corrosion-resistant metals used in modern manufacturing. From architectural structures and medical devices to food processing equipment and marine components, stainless steel is everywhere. But when it comes to fabrication, one question is asked time and again — how to weld stainless steel
In this article, SAKY STEEL explains the process, challenges, and best practices for welding stainless steel. Whether you’re a professional fabricator or just getting started with stainless welding, this guide will help you achieve strong, clean, and corrosion-resistant welds.
Stainless steel is not difficult to weld, but it behaves differently from carbon steel and aluminum. Key considerations include:
Thermal conductivity: Stainless steel retains heat, increasing the risk of warping.
Chromium content: Critical to corrosion resistance, but can be damaged by overheating.
Oxidation sensitivity: Requires clean surfaces and controlled shielding gas.
Distortion control: Stainless expands more during welding and contracts quickly when cooled.
Using the right welding technique and filler material ensures that the final product maintains both its appearance and corrosion resistance.
Tungsten Inert Gas (TIG) welding is the most precise method for welding stainless steel. It offers:
Clean, high-quality welds
Excellent control over heat input
Minimal spatter and distortion
Recommended for: Thin stainless steel sheets, food-grade tanks, pharmaceutical piping, and decorative welds.
Metal Inert Gas (MIG) welding is faster and easier to learn than TIG. It uses a consumable wire electrode and shielding gas.
Ideal for thicker stainless sections
Good for high-volume fabrication
Easier automation for mass production
Recommended for: Structural components, heavy equipment, and general fabrication.
Shielded Metal Arc Welding is used when portability is important or when working in outdoor conditions.
Simple equipment setup
Good for field repairs
Recommended for: Maintenance, repairs, or welding in less-controlled environments.
Selecting the correct filler rod or wire ensures that the weld metal matches the base metal in strength and corrosion resistance.
| Base Metal | Common Filler Metal |
|---|---|
| 304 Stainless Steel | ER308L |
| 316 Stainless Steel | ER316L |
| 321 Stainless Steel | ER347 |
| Duplex Stainless Steel | ER2209 |