Sheet Metal Welding Techniques

Stick, TIG or MIG

• Stick welding uses sticks of base metals that are heated to coat the seams between two pieces of metal, and it's best for rough welding. MIG welding is so called because it uses a metal inert gas that heats up a wire feed that melds the pieces together. This is one of the fastest methods of welding. TIG welding uses tungsten inert gas, which produces a weld through an electrode and is the cleanest weld, used commonly in finish work. It is the slowest welding method.

Copper Shielding

• One of the techniques used by professional welders is the copper shield method. A piece of copper material is placed behind the sheet metal pieces as they are welded together. The copper draws the heat from the welds and dissipates it at a more rapid pace than the two pieces of sheet metal, allowing increased control over the welds and less chance of burn-through or sloppy welds from overheated material.

Chill Blocks

• While they are harder to come by in comparison to simple copper sheets, chill blocks are another technique for spreading heat. At their most basic level they are just blocks of material that help conduct the heat away from the sheet metal pieces. At their most complex level they can include water or liquid-based circulation which helps cool the chill block even more, allowing for greater control than a simple piece of copper.

Flow Control

• As far as generalized techniques go, it is all about flowing the control of the weld during the welding process. While stick welding is the fastest, it is also the sloppiest, but once you understand its limitations you can use it for any rough work and then smooth it down and polish it with grinders and pads. And while TIG welding is the slowest method it also creates the cleanest welds. Always experiment with a scrap piece of sheet metal to determine the best working speed for that particular type of metal before you move into actual production.