How to Weld Copper to Mild Steel

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Things You'll Need

  • TIG welder

  • Welding mask

  • Insulated gloves

  • Filler material

  • Wire-brush

  • Clamps

TIG welding is preferred when welding copper.

Copper is a malleable metal used in a variety of functions including water transportation and ornamental decorations. It is resistant to rust and bonds well with other metals. A TIG welder is used when welding copper to give the weld seam the best appearance and a leak-free bond. Argon gas is used with the TIG welder and a filler material is added to the weld to create a permanent bond between the copper and the steel metals.


Step 1

Place the copper and steel pieces to be welded into their positions. This will be the permanent position of the pieces so be certain they are correct. Clamp the pieces together if needed.

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Step 2

Ground the welder with the alligator clip that is attached to the negative cable of the welder to the workbench or directly to the material you are working with.


Step 3

Put on the welding helmet and insulated gloves. Position yourself over the material that is to be welded.

Step 4

Create a weld pool with the torch at the beginning of the seam that is to be welded. The weld pool will be a small bead of melted metal that has been formed by the two materials. The torch should be held at a 75 to 80 degree angle relative to the seam being welded and at an eighth to a quarter inch above the surface.


Step 5

Hold the filler material at a 15 degree angle to the seam. Gently dab the filler into the pool created by the torch. Drag the weld pool along the length of the seam while dabbing the filler material into the melted metal. Continue along the seam until you reach the end of the area to be welded.


Step 6

Clean the weld with a wire-brush to remove any burrs or weld splatter that may have occurred. The weld can be painted or left as is when finished.


Always weld in a well-ventilated area.


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