Magnesium alloy costs between $7 and $16 per pound and is suitable for alternating current (AC) Tungsten Inert Gas, or TIG welding. It’s lightweight, easy to cast, and vibration-absorbing.
Low-carbon steel, or mild steel, costs between $10.50 and $11.50 per pound. Apart from its relatively low cost, it’s also a popular choice because of its ease of welding. This versatile metal alloy is highly cost-effective, doesn’t shrink much, is easy to work with, and is suitable for all types of welding apart from AC TIG.
The cost of stainless steel ranges between $13 and $15 per pound. Welders like stainless steel for its ease of use and corrosion resistance. However, it's important to know what you're working with; martensitic-grade stainless steel has a habit of cracking, so it isn't the best choice for welding. Instead, stick with ferritic and austenitic grades. Stainless steel works well with all types of welding, apart from AC TIG.
Aluminum costs between $14 and $22 per pound. It’s a little more challenging to work with than steel but still very versatile, corrosion-resistant, and lightweight. Aluminum is best for stick, Metal Inert Gas (MIG), and AC TIG welding.
Copper and brass alloys cost between $24 and $29 per pound. They’re popular because of their thermal and electrical conductivity and high wear and corrosion resistance. While high-quality copper and brass are reasonably easy to work with, some alloy mixes, including cheaper alloys with impurities, can easily crack, form craters, oxidize, or corrode. Lower-grade alloys also have weaker electrical and thermal conductivity. Copper and brass are best suited to direct current (DC) TIG welding.
The average cost range of cast iron costs is $38 to $79 per pound. While expensive, if handled correctly, it produces strong, durable welds. However, it does require a high degree of skill because of the high carbon and silicon content. If it isn't pre-heated, or if the temperature changes are too aggressive and rapid, it can crack or result in craters. Plus, the welds won't be as strong. Cast iron is suitable for stick welding.
Titanium is one of the most expensive options, costing $60 to $85 per pound. Working with this type of metal requires the skills of a master welder. It's a highly effective, durable option but does require extra equipment and full coverage with shielding gas to prevent oxidation. Titanium is suitable for DC TIG welding.
Welding Cost by Type
There are numerous methods of welding available including:
Typically, the nature of the project and type of metal will determine the welding method — not all methods are usable for all metals and projects. A professional welder will decide the most appropriate welding method for your project. Below, we’ve included welding cost estimation for some of the most common welding methods.
Stick Welding
Stick welding costs start around $100 and can climb to $1,000. Also known as shielded metal arc welding, stick welding uses extreme heat to melt two separate pieces of metal together. The heat comes from an electric arc created between a base metal workpiece and the tip of a filler metal electrode. The metals become strong as they cool.
The equipment for stick welding is simple and inexpensive, plus it can work with most common metals and alloys. Also, this welding does not require flux—the gas is inbuilt into the electrode.
Hiring a MIG welding pro will set you back at least $250. Also called Gas Metal Arc Welding (GMAW), this welding method uses a solid wire electrode to produce a weld. This wire is heated and continuously fed into a weld pool from a welding gun. The two base metals are melted together. Alongside the electrode, the gun feeds a shielding gas (usually argon or carbon dioxide, or a mixture of both) that protects the weld pool from airborne contaminants and prevents oxidation.
Tungsten Inert Gas (TIG) Welding
With Tungsten Inert Gas welding, or TIG welding, expect to pay at least $250. TIG welding uses a tungsten non-consumable electrode to weld two disparate pieces of metal together. A foot pedal controls the heat of the arc. Unlike MIG, which can use a variety of shielding gases, TIG welding projects require 100% argon gas as its shielding component.
Gas Welding
Gas welding costs start at around $150. It’s one of the oldest types of welding. Here, a flammable gas, such as acetylene and oxygen, is super-heated to weld two pieces of metal together. Gas welding has many applications and is a popular choice in many general repair shops.
Forge Welding
Forge welders charge between $15 and $25 per hour (plus materials) if you take the item to their shop. This type of welding involves heating two pieces of metal, then using force, like hammering, to join them together. This type is a form of blacksmithing and is among the oldest types of welding. Its use is, however, restricted to a few metals such as low-carbon steel and wrought iron.