How to Weld Rusted Metal
Some people weld metal as a part of their job; others weld to create art. Either way, it provides a chance to create structure. Welding is enjoyable to some but can also be a technical process. Typically, metal materials are stored in moisture-rich environments that create rust. Because of this, welders must have a clear understanding of how to weld rusted metal.
Things You'll Need
- Welder
- Grinder (optional)
- Steel wool brush
- Silicone carbide abrasive paper
- Alkali-acid solution
- Rubber gloves
- Rags
- Welding mask
Instructions
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Move your metal to a location that's safe for cleaning and welding. The area should provide plenty of ventilation and be free of any flammable materials. This area should also have a solid floor, such as concrete or asphalt. If you don't have access to an area like this, complete your welding project outside.
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Use the grinder to remove the rust from the metal. Apply pressure with the grinder in small, circular motions. Concentrate only on the areas where the weld will be; it's not necessary to remove all rust from the metal. Use the steel wool brush to remove additional rust. Saturate a rag with the alkali and acid solution while wearing gloves. Remove any dust or small particles from the area where you'll be welding. The metal is now prepared for welding.
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Put on the welding helmet, gloves and apron before welding. Set up your welder and turn it on. Set the amperage of the welder to a level that's appropriate to the type and thickness of the metal, which should be between 90 amps and 120 amps. Strike a welding arc with a welding lighter. Place the metal in the position you want to weld.
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Hold the arc at a 90-degree angle and slowly move the weld in a straight line across the seam. When the metal cools, remove any loose materials with your steel wool brush.
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Tips & Warnings
Always wear non-flammable protective clothing while welding.
References
- Photo Credit Jupiterimages/liquidlibrary/Getty Images
