If it’s your first time welding, it might seem like a challenging task. And the difficulty increases manifold if the metal is thin.
In this case, I see many people opting for MIG welders. But that is not always a possibility since they are pretty expensive and come with accessories that are pricey. And the worst part is that they are pretty big in size and hence not portable. As such, I receive many queries from my readers about what is the best alternative in a scenario like this.
Well, I would say there’s nothing better than using a welding arc. Hi! I am Stacy Smith, and today, in this guide, I will tell you how to weld thin metal with arc welding in an effective manner. Read it thoroughly, and you will get a glimpse into all the things that you need to take into consideration to become a pro at arc welding.
So, without any delay, let’s dive right in!
Popularly known as the stick welding process, you can opt for this technique if you are stuck between a coated electrode and a workpiece. Due to the formation of electric current, the workpiece and the rod can sometimes melt together and form a pool of mess. And the coating (flux) plays a crucial role to prevent the weld from contamination and oxidation.
This method is also known as the metal inert gas welding (MIG) process. In this process, you need to feed a heated solid wire electrode to a welding pool. This helps generate a lot of heat and enables you to join the metallic surfaces together. At the same time, the weld is continuously fed to inert gases in order to protect it from contaminants.
From my years of welding experience, I can say that GNAW is one of the best ways that you can implement to join thin metallic sheets.
Related: How to Weld 20 Gauge Sheet Metal
When compared to carbon steel, stainless steel shows less thermal conductivity, and thus you can rest assured that it won’t transfer much heat. As a result, there is a considerable spatter, and that might result in your metallic bead not becoming as levelled as you might have wished.
In order to enhance the bead appearance, I would advise not to make use of any electric source that comes with a tit or an induction control mechanism. If you do that, the inductance can slow down the response time of the electric supply, and the slope will limit the possibility of a short circuit.
I do this in my workshop as it helps me gain better control over the wire burnoff. You can keep increasing the speed to enhance circuit speed/second. And on your best days, it will range between 20 and 80 with ease.
When you do padding, make sure that you use the welding equipment at a low current flow. During this process, you strike an arc instead of a touch start. As a result, you end up implementing the much popular match striking method.
The moment your arc starts forming, it is best to strike the metal sheet and then eventually take it off, all the while ensuring that you maintain the arc. And as you keep moving to the work area, keep making some straight lines.
In case there is a weld build-up, make sure that you clean it up immediately. Trust me- you will thank me later for this advice! If the weld gets cold and dried out, you will have a very hard time removing it.
When you are welding thin metal, remain especially cautious to not burn your material. And for that, it is crucial to maintain the right angle for the torch. Keep it in overhead, flat or horizontal positions, and your problem will be sorted.
If you are indulging in SCT( short-circuiting transfer) welding, you can use a small contact tip between 0.26 and 0.6 inches. The more distance you keep, the more unstable an arc you create. And this can cause a high amount of resistance between the workpiece and the tip.
I always recommend my readers maintain maximum caution when selecting the wire diameter, as that has a direct impact on the quality of welding.
If you are working with stainless steel, a wire diameter of 0.030 or 0.045 works perfectly fine. On the other hand, if you plan on using carbon steel, the wire diameter should ideally be 0.030,0.035 or 0.045.
Likewise, when you are working with extra-thin metal, going for a lesser wire diameter is always the best option. Just make sure that it is not too thin to the point where it becomes dysfunctional.
When welding, you will need additional welding rods (E6018 or E7018/16) and a DC welder, which has a capacity of at least 20-25amps. Even if your sheet is as thin as 0.021 inches, this combination will work just fine.
That’s all I have for today’s guide.
It is true that welding can seem like a complicated task when thin metals are involved. But as you have seen, arc welding definitely is the most popular and the easiest way. And to get the best result, all that you require is to follow the tips that I have shared with you.
Get the diameter of the wire right, and use the correct voltage and amperage. Conduct some research by yourself, and in case you have any doubts, do not forget to write to me in the comments section below. With the right combination, you will be able to weld almost any joint without any trouble.
Keep a watch on this space for more exciting reads. And until next time, adios!
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