Welding sheet metal is a tricky process that requires focus and special tools. Since the material is thin, you must maintain the right level of heat to prevent brittle joints and burning through the surface. Here are some tips to help you succeed with two techniques.

MIG Welding

Metal inert gas (MIG) welding is a beginner-friendly technique that offers more room for error. With this equipment, choose the smallest wire diameter available. This tool will require less heat, reducing the risk that the weld will burn through and giving you more control over the weld bead.

MIG welders should only use body filler metals that are thinner than the base metals. Gases with high argon content are also recommended due to their lower heat requirements. Make short and quick strokes to preserve the material’s shape. Butt welds are best, as they prevent moisture buildup and hold up well under stress.

TIG Welding

Gas tungsten arc (TIG) welding creates more precise results on thin materials, but generally requires more experience. TIG equipment with a pulse rate of 100 pulses per second will minimize the risk of melted panel edges, while a pointed electrode should improve arc stability.

To control heat, welders should stick to low amperage. For carbon steel, use 1 amp per 0.001-inch of thickness. For stainless steel, this should be 2/3 of an amp per 0.001-inch of material. Again, the filler metal should be thinner than the base metal. Shielding the backside of the weld will prevent oxidation, reducing the risk of excess heat and surface imperfections.

No matter how experienced you are at welding, count on Wayne Oxygen & Welding Supply Co. for all the supplies you need. With locations in Waynesboro, Charlottesville, and Harrisonburg, VA, they’ve been a one-stop shop for welders in the community since 1959. Their knowledgable staff will answer any questions you have to help you get the job done right. Visit them online to learn more about their products, or call (540) 942-4145 to ask about their stock.