MIG Welding Stainless to mild steel?

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I have a Lincoln PowerMig 256. I am fixing to build new exhaust for my Jeep. I have headers that are mild steel, I want to use V band clamps to hook them to my new stainless exhaust. Can I weld the stainless steel flange to my mild steel headers or will that not hold up?72 Chevy Cummins Project94 3500HD Welding Rig build Sold NOV 2011
Reply:if you are going to tig it use 309 fillerMiller Xmt 350Lincoln Ln-25Ahp 200xSmith Gas Mixer AR/HTig is my Kung FuThrowing down dimes and weaving aboutInstagram http://instagram.com/[email protected]
Reply:Yeah, you'll want 309 wire.  The stainless job I'm working on right now has a lot of .065 wall thickness welded to .120 wall, and I'm using .023 wire on it and a 10' gun length.  The welds are turning out beautiful with lots of penetration and extremely low spatter.  I think I'm running around 18.0V and 380 ipm wire speed.  You'll probably want a little less for your project.  I had to switch tri-mixes from my supplier's proprietary gas which wasn't working worth a hoot to the standard 90% Helium, 7.5% Argon, 2.5% CO2.  It wasn't too cheap at $75 for a 282 cf bottle.  Wire was about $8/lb and the smallest rolls that will fit my feeder spindle are 10-lb rolls.  Don't forget an .023 liner, tips, and drive rollers if you don't already have them.It can be an expensive proposition to MIG stainless.  I would use TIG as Wookie suggested above, if you already have the equipment and skill.  If not, then yes, it is possible to get beautiful stainless welds with MIG.It would be a lot cheaper to TIG if you don't already have the MIG consumables.Last edited by tbone550; 03-10-2012 at 07:33 AM.
Reply:Well I think this settles it, i am going to go with mild steel and have it coated. I am wanting to buy another tig, but right now it is not in the budget.72 Chevy Cummins Project94 3500HD Welding Rig build Sold NOV 2011