Corten steel welding (or weathering steel welding) is widespread because of its looks, and mechanical properties and is essential for various applications, including constructing bridges, buildings, and sculptures.
This article aims to be a comprehensive guide on corten steel welding, covering everything from the outstanding mechanical properties of corten steel to the various methods to weld corten steel.
Contents
- 1 Understanding weathering steel
- 2 Factors to consider before weld corten steel
- 3 Safety considerations
- 4 Post-welding treatment
- 5 Conclusion
- 6 FAQ
- 6.1 Is Corten steel weldable?
- 6.2 What is the best welding rod for Corten steel?
- 6.3 What gas is used for welding Corten?
- 6.4 What filler metal for Corten steel?
- 6.5 What is mild steel?
- 6.6 Are corten steel and mild steel properly welded together?
- 6.7 What can be called a stainless steel material?
- 6.8 What are common corten steel grades?
Understanding weathering steel
Corten steel, which is also referred to as weathering steel, is a high-strength corrosion-resistant material alloy that can develop a protective layer of rust when it is exposed to the elements.
Corten steel is a low-alloy steel that contains small quantities of copper, chromium, nickel, and phosphorus.
Because of its mechanical properties, including high tensile strength and corrosion resistance, corten steel is commonly used in outdoor applications. Corten steel is also weldable and can be formed into different shapes and sizes.
However, its long-term durability and low maintenance needs make this weather-resistant steel a cost-effective choice over time.
Factors to consider before weld corten steel
Before beginning any weld corten steel steps, here are some important factors to consider.
Pre-welding considerations
Proper preparation before welding corten/weathering steels can help ensure the success of welding corten steel and the overall quality of the finished product.
Before beginning the corten steel welding, it is important to carefully clean the surfaces that will be welded.
Any rust, oil, or other contaminants should be removed from the surface using a wire brush or sandpaper. This helps to ensure that the welding corten steel produces a strong and reliable bond.
Another important pre-welding consideration is the design and layout of the welding joints. They should make the welding joints accessible and easy to weld.
The layout of the joints should be such that they can accommodate the necessary weld size and ensure a strong and reliable welding corten steel.
Proper design and layout of the corten steel welding joints can also help reduce welding defects, such as cracking or distortion.
The weather and temperature can have a significant impact on the corten weathering steel welding and the quality of the finished product.
Corten steel welding methods
There are several welding methods for corten steel.
- Stick welding corten steel
This is a commonly employed welding method that is easy to learn and can be used in all weather conditions.
It involves using a stick electrode to make an arc for it to melt the metal and fuse it.
- TIG welding corten steel
TIG welding is another pretty common corten steel welding method that produces high-quality welds.
TIG welding involves using a tungsten electrode to create an arc that melts the metal and a separate filler rod to add material to the weld.
- MIG welding corten steel
MIG welding is a versatile corten steel welding method. MIG welding can be used to weld a variety of metals, including corten steel.
MIG welding involves using a wire electrode that is fed through a welding gun and melted to create the weld.
TIG/MIG filler wires are different but TIG/MIG filler wire should have high corrosion resistance.
- Flux-cored arc welding corten steel
This corten weathering steel welding method can be called similar to MIG welding. But this one requires a hollow wire electrode, and the last one is filled with flux.
The flux protects the weld from oxidation and can improve the overall quality of the weld.
The choice of corten steel welding method will depend on the specific application, the atmospheric corrosion resistance of the base metal, and the skill level of the welder.
It is important to select the appropriate method and equipment to ensure a durable and really strong weld.
Best practices for welding weathering steel
Welding corten steel requires practices that can help ensure a successful and high-quality weld.
Here are some general tips to keep in mind:
- Properly clean the welding surface to remove any contaminants such as oil, rust, or paint.
- Employ the correct welding wire. Welding wire choice depends on the project.
- Use a low hydrogen welding electrode with a basic coating.
- Use a backstep technique when welding to help prevent warping and distortion.
- Maintain a consistent travel speed and heat input to prevent overheating or underheating.
- Use a suitable shielding gas, such as argon, to protect the weld from contamination and oxidation.
- Monitor the welding parameters and adjust them as needed to maintain a stable arc and prevent defects.
- Allow the corten steel weld to cool slowly to prevent cracking or other issues.
- Inspect the weld and surrounding area thoroughly for any defects or issues before finishing or post-weld treatment.
It is important to note that these best practices may vary depending on the specific welding application and technique being used.
Consulting with a professional corten steel welder or engineer may also be helpful to ensure the best results.
Safety considerations
Corten steel welding can pose certain safety hazards that should not be overlooked. Here are some safety considerations to keep in mind.
Corten steel welding safety equipment and procedures
When welding corten steel, it’s important to follow proper safety procedures and use the appropriate equipment to prevent injury and minimize health risks.
Safety equipment should include a welding helmet with a proper shade level, welding gloves, protective clothing, and welding boots.
Additionally, proper ventilation and respiratory protection should be used to avoid inhaling harmful fumes and particulates.
Welders should also be trained in proper welding techniques and safety procedures to ensure the best results and minimize the risk of accidents.
Health risks associated with welding corten steel
Welding corten steel can pose several health risks to welders.
The corten steel welding process produces hazardous fumes and gases that can cause various respiratory problems.
Inhaling these fumes and gases can lead to acute symptoms like coughing, chest tightness, and shortness of breath, as well as chronic conditions like asthma, emphysema, and lung cancer.
The health risks associated with welding weathering steel are mainly due to the metal’s high content of copper, nickel, and chromium.
When heated during welding, these elements can form toxic fumes that are harmful to human health.
Moreover, the welding process can also produce harmful radiation, such as ultraviolet (UV) and infrared (IR) radiation, which can cause skin damage and eye injuries.
Safety precautions
Therefore, welders need to take proper safety precautions, such as using protective equipment, working in well-ventilated areas, and following safe welding practices.
Welders should wear appropriate respiratory protection, such as a powered air-purifying respirator (PAPR) or a supplied-air respirator (SAR), to avoid inhaling harmful fumes and gases.
Additionally, welders should use protective clothing, such as welding gloves, aprons, and sleeves, to protect their skin from radiation and heat.
Post-welding treatment
Post-welding treatment is an important step to weld corten steel to ensure that the welded area maintains its structural integrity and aesthetic appeal.
Here are some things to keep in mind regarding post-weld corten steel treatment.
Importance of post-welding treatment
Corten steel forms a layer of rust when exposed to weathering, but the welding process can disrupt this layer, leaving the welded area vulnerable to corrosion.
Proper post-welding treatment can help to restore the protective layer and prevent corrosion.
Best practices for post-welding treatment
It is important to thoroughly clean the welded area before applying any treatment.
Additionally, the chosen treatment should be applied uniformly and left to dry completely before the structure is exposed to the elements.
It is also crucial to follow the manufacturer’s instructions for any patina solution or coating that is applied.
Conclusion
Corten steel (weathering steel) is a popular material for outdoor structures due to its unique weathering properties and aesthetically pleasing appearance.
Welding corten steel can be challenging due to its composition and properties, but with the right techniques and precautions, it can be successfully welded.
FAQ
In this section, we have included several frequently asked questions about welding corten steel along with their brief answers.
Is Corten steel weldable?
Corten steel can be welded, but it is crucial to utilize appropriate welding techniques for optimal outcomes.
What is the best welding rod for Corten steel?
Choosing the correct welding rods for corten steel varies based on the welding technique (for instance, TIG welding) and the intended use. The most popular rods are АWS Е7018-W1 and ЕR70S-6.
What gas is used for welding Corten?
Corten steel welding typically involves using argon as the shielding gas. However, it is also possible to use a combination of argon with CO2 or helium for better results.
What filler metal for Corten steel?
To ensure the appropriate corten steel weld strength alongside corrosion resistance, selecting the right filler metal is crucial when working with corten steel.
Choosing a matching or slightly overmatching filler metal with high corrosion resistance and tensile strength is generally recommended.
Some commonly used options with almost the same corrosion resistance and tensile strength include AWS A5.5 ER70S-6, AWS A5.5 ER80S-W, and AWS A5.29 E81T1-W2.
What is mild steel?
Mild steel is one kind of carbon steel. Mild steel has a low carbon content ranging from 0.05% to 0.25% by weight. Mild steel finds widespread use in various applications.
Mild steel usually is easier to purchase due to its affordable pricing. Overall, mild steel is called a widespread choice for different projects. Mild steel can be easily welded.
Are corten steel and mild steel properly welded together?
Mild steel and corten steel are both types of steel. But they represent a little bit different mechanical properties and possible uses.
But although mild steel and corten steel don’t have the same properties and uses, they can be welded together using the appropriate techniques and materials.
What can be called a stainless steel material?
Stainless steel represents an alloy of steel that contains at least 10.5% chromium by mass.
What are common corten steel grades?
There are АSТМ А588, АSТМ А606-4, СОR-ТЕN А, and СОR-ТЕN В, and АSТМ А242.
