Welding Stainless to Steel

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One of the projects I will use my new welder for will be bumpers for my Jeep.  I have a design in mind but as of now I am not at all certain if this will work or not.  If it is possible I will need to work it out prior to trying the bumper build.Below is a crude illustration of part of the bumper.  The dark represents regular weld steel in 3/16" and the silver represents the stainless area of unknown thickness for now.Again, this is a crude representation and doesn't look exactly like what I have in mind but it should be close enough to give you the idea of what I want to do.Is it possible to weld the stainless to the plain steel to make up what I have shown?  Can it be done to where it is structurally sound?What is the process necessary to achieve this?
Reply:You can mig it with 309 but why would you use 1/2 steel and 1/2 stainless anyways?
Reply:Originally Posted by Country MetalsYou can mig it with 309 but why would you use 1/2 steel and 1/2 stainless anyways?
Reply:I don't think Country Metals meant inches but rather using each metal.Leo
Reply:Ahh!  I apologize.  Ok, well, the stainless is simply for a certain"look" that I want to achieve.Last edited by MWalden; 06-19-2011 at 09:58 PM.
Reply:Use 309 stainless wire/rod for stainless to mild steel.  If you use a MIG, use Tri-Mix gas.  Don't worry about the black soot, it comes off easy with a quick wipe or brushing.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:Originally Posted by MarkBall2Use 309 stainless wire/rod for stainless to mild steel.  If you use a MIG, use Tri-Mix gas.  Don't worry about the black soot, it comes off easy with a quick wipe or brushing.
Reply:For what your going to be using it for, you can weld it with any steel electrode just fine.Have we all gone mad?
Reply:SMAW with a stainless steel rod needs a big learning curve. It is my last choice for welding stainless or any kind. If you have access to a DC stick machine, then get a tig conversion and a bottle of argon and Tig weld it with 309.
Reply:True, but the weld may "rust" or discolor if you don't at least try to use a stainless wire/rod.SMAW, you would have to find the rod.  If I remember correctly, I saw 309 rod online, but don't remember where.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:For that application id say you could use SMAW (which keeps it simple)I did something similar with 316 lincoln red baron.steel and stainless are very similar. and if you are not so worried about the corrosion resistance then it i'll be fine.you could probably use 7018.dont forget the pics!G
Reply:........ unless the stainless that you are going to weld is real thin.16gauge might work with SMAW if you are careful, maybe a little thinner, but not much.G
Reply:Originally Posted by gordfraser........ unless the stainless that you are going to weld is real thin.16gauge might work with SMAW if you are careful, maybe a little thinner, but not much.
Reply:Originally Posted by Country MetalsSMAW with a stainless steel rod needs a big learning curve. It is my last choice for welding stainless or any kind. If you have access to a DC stick machine, then get a tig conversion and a bottle of argon and Tig weld it with 309.
Reply:SMAW 309 rod. Any LWS should have it. As stated before, stainless stick welding takes practice...it is a different animal.If it is a one off project might be better off fitting it up and paying someone to tig it. A full tig set up is gonna cost a few bucks.Of course when you're done you still have the tig equipment.I've welded stainless/carbon with 6010 in "gotta have it now",  low stress situations. Works, but definitely not the way to go on a project without constraints. AlA man is judged by what's between his legs...always ride a good horseMiller DialArc HFLincoln Classic 300DThermal Arc 181iPowermax 45Scotchman Ironworker(2) BridgeportsOkomota Surface GrinderAutoCAD 2010
Reply:Originally Posted by SmokinPRanchSMAW 309 rod. Any LWS should have it. As stated before, stainless stick welding takes practice...it is a different animal.If it is a one off project might be better off fitting it up and paying someone to tig it. A full tig set up is gonna cost a few bucks.Of course when you're done you still have the tig equipment.I've welded stainless/carbon with 6010 in "gotta have it now",  low stress situations. Works, but definitely not the way to go on a project without constraints. Al
Reply:Originally Posted by MWaldenI have an AC/DC stick machine but I have no idea what the cost of a tig conversion would cost me and I bet it is out of my budget anytime soon.
Reply:If you think you will be doing work in the future that will use the tig it is a good investment. If you do much stainless at all it's definitely the way to go.Go with the 309 for carbon to stainless if you go with SMAW. Check the manufactures sites for parameters and tips. Try to keep the stainless as close to the carbon thickness as you can to keep washing in to a minimum. BTW nice drawing. What are you using to cut the stock?AlA man is judged by what's between his legs...always ride a good horseMiller DialArc HFLincoln Classic 300DThermal Arc 181iPowermax 45Scotchman Ironworker(2) BridgeportsOkomota Surface GrinderAutoCAD 2010
Reply:Originally Posted by Country MetalsCyberweld - Just rough pricingWP17 torch - 95.65     http://store.cyberweld.com/db150ampairt.htmlTig/Stick adapter - 15.04       http://store.cyberweld.com/tigtopoad10.htmlFree Shipping in US - 0.00Total: 110.69You will also need to buy, rent, or borrow a agron bottle and regulator from someone.
Reply:Humpf............. 50 years old is just gettin broke in.I'm 54, just got a lathe last year, a mill 1 month ago................Never too old to learn something new.  Go for it with the TIG if possible, if not 309 wire in the MIG.  A hundred bux isn't much to spend to learn a new hobby.  And once you learn it, work on mastering it.MarkI haven't always been a nurse........Craftsman 12"x36" LatheEnco G-30B MillHobart Handler 175Lincoln WeldandPower 225 AC/DC G-7 CV/CCAdd a Foot Pedal to a Harbor Freight Chicago Electric 165A DC TIG PapaLion's Gate Build
Reply:You don't need a hi-freq box to DC TIG, that would only be needed for AC. If you go with TIG, remember to connect your TIG rig to the Neg welder terminal. Whatever process you choose, the 309 filler is the best for that application. Don't be afraid to try the Stick, just get some scrap and try a few beads before moving to your finished project. Mild steel scrap is fine for practicing on.
Reply:Originally Posted by MarkBall2Humpf............. 50 years old is just gettin broke in.I'm 54, just got a lathe last year, a mill 1 month ago................Never too old to learn something new.  Go for it with the TIG if possible, if not 309 wire in the MIG.  A hundred bux isn't much to spend to learn a new hobby.  And once you learn it, work on mastering it.
Reply:"Field tig" (the adapter that I previously linked to) uses scratch start which is not a match strike, it is more of a touch and raise slightly. You only need to make a connection to enable amp flow, once started it will continue when you raise the tungsten off the metal. There are many sections on here and on the web about learning to tig weld. You will actually use less amps with tig then stick.Stick - DCEP (electrode positive)Tig - DCEN (electrode negative)Your best bet is to get some steel 1/8" plate to run flat beads and flatbar to cut 6" lengths and start welding them together in a T joint, since this will be the same type of join you are showing in your picture.Steel and Stainless Steel basically weld the same when tigin them.
Reply:Originally Posted by Country Metals"Field tig" (the adapter that I previously linked to) uses scratch start which is not a match strike, it is more of a touch and raise slightly. You only need to make a connection to enable amp flow, once started it will continue when you raise the tungsten off the metal. There are many sections on here and on the web about learning to tig weld. You will actually use less amps with tig then stick.
Reply:If it is just a bumper I would weld it with your regular mild steel mig wire... I have done it a lot and it works fine. Same with tig, I usually just use er70s2..HTP Invertig 201Lincoln Idealarc SP250Miller 180 AC StickBy farmall:They should have held the seagull closer to the work, squeezing evenly for best deposition.Originally Posted by Country MetalsCyberweld - Just rough pricingWP17 torch - 95.65     http://store.cyberweld.com/db150ampairt.htmlTig/Stick adapter - 15.04       http://store.cyberweld.com/tigtopoad10.htmlFree Shipping in US - 0.00Total: 110.69You will also need to buy, rent, or borrow a agron bottle and regulator from someone.
Reply:Originally Posted by DSWThe torch listed will work, but you'll waste a ton of gas. You want the WP17 V torch instead. The "V" denotes the torch with the gas valve on the handle, and they run a bit more (but not "oh my God"). this lets you turn on and off the gas at the torch rather than at the cylinder. The only other "down side" is that you won't have a pedal to adjust the amperage as you weld. That makes some things easier, but not imposible. Guys use a basic scratch start tig like this everyday in the field.
Reply:Originally Posted by DSWThe torch listed will work, but you'll waste a ton of gas. You want the WP17 V torch instead. The "V" denotes the torch with the gas valve on the handle, and they run a bit more (but not "oh my God"). this lets you turn on and off the gas at the torch rather than at the cylinder. The only other "down side" is that you won't have a pedal to adjust the amperage as you weld. That makes some things easier, but not imposible. Guys use a basic scratch start tig like this everyday in the field.
Reply:There are ways of making that happen, but you are starting to get into bigger dollar signs now. Like a HF box runs 1300+ new, I got one for 350 off craigslist (brand new, used 3 times and then they bought a syncrowave). I have only used mine about 20 times until I bought a dynasty.