Although welding stainless steel may not be as difficult as welding aluminum, the metal does have its specific properties that vary from your more common steels.
When MIG welding on stainless, you usually have three choices of transfer depending on your equipment: spray-arc, short-circuiting, or pulsed-arc transfer.
Stainless steels or, more precisely, corrosion-resisting steels are a family of iron-base alloys having excellent resistance to corrosion. These steels do not rust and strongly resist attack by a great many liquids, gases, and chemicals. Many of the stainless steels have good low-temperature toughness and ductility. Most of them exhibit good strength properties and resistance to scaling at high temperatures. All stainless steels contain iron as the main element and chromium in amounts ranging from about 11% to 30%. Chromium provides the basic corrosion resistance to stainless steels. There are about 15 types of straight chromium stainless steels.
The stainless steel of choice in the food services industry is the austenitic
300 series. The stainless used for good pots (like Vollrath) is usually 304.
Less expensive pots are often made of 303 alloy stainless which is less
weldable and is quickly attacked by chlorinated cleaners. Other stainless
kitchen equipment, like utensils, are typically Ferritic stainless, which has
less Chromium and Nickel and is less acid-neutral.
Nickel is added to certain of the stainless steels, which are known as chromium-nickel stainless steel. The addition of nickel reduces the thermal conductivity and decreases the electrical conductivity. The chromium-nickel steels belong to AISI/SAE 300 series of stainless steels. They are nonmagnetic and have austerity micro structure. These stainless steels contain small amounts of carbon because this element has tendency to make chromium carbides, which are not corrosion resistant. Carbon is undesirable particularly in the 18% chromium, 8% nickel group.
Manganese is added to some of the chromium-nickel alloys. Usually these steels contain slightly less nickel since the chromium-nickel-manganese alloys were developed originally to conserve nickel. In these alloys, a small portion of nickel is replaced by manganese, generally in a two-to-one relationship. The AISI/SAE 200 series of stainless steels are the chromium-nickel-manganese series. These steels have an austerity micro structure and they are nonmagnetic.
Molybdenum is also included in some stainless steel alloys. Molybdenum is added to improve the creep resistance of the steel at elevated temperatures. It will also increase resistance to pitting and corrosion in many applications.
Stainless steels can be welded using several different procedures such as shielded metal arc welding, gas tungsten arc welding, and gas metal arc welding.
These steels are slightly more difficult to weld than mild carbon steels. The physical properties of stainless steel are different from mild steel and this makes it weld differently. These differences are:
What Makes A Steel Stainless?
The alloying addition of Chromium and Nickel to the iron creates a significant
percentage of those atoms at the surface, which form tenacious oxides that
seal the surface and prevent oxidation of the iron. The process known as
"Passivation" for stainless steel, as discussed in the article "Care and
Feeding of Stainless Steel" by Micah Millspaw in the July/August issue of
Brewing Techniques, is a common means of improving this protective oxide layer
through the use of oxidizing acids. Anodizing aluminum alloys is similar in
that a solid aluminum oxide barrier is created to prevent further corrosion.
Anodized (black) aluminum cookware (Magnalite, Calphalon) is acid neutral /
acidic food resistant like stainless steel because of this heavy oxide layer.
Plain (bright) aluminum cookware does not have the degree of surface oxides
necessary to prevent reaction with corrosive media.
Joining of Steel and Brass/Copper
Stainless steel is routinely welded, but it must be done under an inert gas
atmosphere. The most reliable method for welding stainless is the Tungsten
Inert Gas (TIG) process, aka. GTAW and Helio-Arc. TIG welding has the
advantage of a small weld head, lower heat input is required and filler metal
is optional. The other common welding methods for stainless steel, Metal
Inert Gas (MIG) and Shielded Metal Arc Welding (SMAW), are not as well suited
for welding thin sections like beer keg walls. MIG is commonly used for all
types of stainless welding but the weld gun must be held close to the work and
this decreases its effectiveness in tight areas. MIG equipment will be more
available to a do-it-yourselfer and should provide a satisfactory joint. SMAW
is commonly used for welding thicker pipe and tanks. It has the disadvantage
of obscuring of the weld joint during the pass and the slag must be removed
between passes. Equipment and electrode filler rods are readily available,
however this welding process is not recommended for this application. The
welder does not have the control necessary to insure a good weld.