Welding Services for Corrosion-Resistant Metals

Aluminum and stainless steel welding for equipment, railings, and custom projects in Johnston, Colorado.

When your project in Johnston requires welding on aluminum or stainless steel, you need a welder who understands how these metals behave under heat and how to produce clean, strong joints without warping or contamination. Rhoades Welding LLC performs specialized welding on aluminum and stainless steel for equipment repairs, railing systems, structural components, and custom fabrication projects where corrosion resistance and long-term performance matter.

Aluminum welding uses TIG or MIG processes with inert gas shielding to prevent oxidation during the weld, and the metal is cleaned thoroughly before welding to remove surface contamination that can weaken the joint. Stainless steel welding requires similar shielding and often involves back purging to protect the inside of the weld from discoloration and corrosion. Both metals require precise heat control to avoid distortion, especially on thin material, and the finished welds are clean and uniform without excessive spatter or discoloration.

If you need aluminum or stainless steel welding for a project in Johnston, get in touch to discuss material specifications and welding requirements.

Why Aluminum and Stainless Steel Require Different Welding

Your project in Johnston involves material preparation, correct filler selection, and gas shielding to protect the weld pool from atmospheric contamination. Aluminum is cleaned with a stainless wire brush or solvent to remove oxide layers, and welding is performed with alternating current to break up surface oxides during the process. Stainless steel is welded with direct current and often uses a backing gas inside the joint to prevent sugaring, a form of oxidation that weakens the weld and causes discoloration.

After welding, you will notice that the joints are smooth and free of porosity, the metal has not warped or pulled out of alignment, and the surface retains its corrosion resistance without flaking or rust. Clean welds result in structural and functional components that perform reliably under long-term exposure to moisture, chemicals, and temperature changes.

The service is used across equipment repairs, railings, custom fabrication, and structural components, and includes experience with different material thicknesses from thin sheet metal to heavy plate. It does not include post-weld polishing, anodizing, or passivation unless specifically requested and quoted.

What to Expect When Welding These Metals

Customers often ask why aluminum and stainless steel cost more to weld, how the welds will look, and whether these materials can be repaired the same way as mild steel.

What makes aluminum harder to weld than steel?
Aluminum conducts heat rapidly and forms an oxide layer that melts at a higher temperature than the base metal, making it easy to burn through thin sections or create weak joints. Successful aluminum welding requires AC current, thorough cleaning, and precise heat control to avoid distortion.
How do you prevent stainless steel from rusting after welding?
Stainless steel resists corrosion due to a chromium oxide layer that forms on the surface. Welding disrupts this layer, so the weld must be shielded with inert gas during the process and sometimes cleaned or passivated afterward to restore corrosion resistance.
Why do some stainless steel welds turn brown or blue?
Discoloration occurs when the back side of the weld is exposed to oxygen during welding, causing oxidation that weakens the joint and reduces corrosion resistance. Back purging with argon gas prevents this by displacing oxygen inside the joint while welding.
What types of projects require aluminum or stainless steel instead of regular steel?
Aluminum is used when weight matters or when the component will be exposed to moisture without paint or coating. Stainless steel is chosen for food processing equipment, outdoor railings, chemical environments, and architectural projects where rust would be unacceptable.
How thick can aluminum and stainless steel be welded?
Thin material from sixteen gauge up to quarter-inch plate can be welded with TIG for maximum control. Thicker stainless steel can be welded with MIG or stick processes when appearance is less critical and penetration is the priority.

Rhoades Welding LLC provides aluminum and stainless steel welding services throughout Johnston, Colorado, using shielding gas, proper filler material, and heat control to produce clean welds suitable for corrosion-resistant applications. Reach out to discuss your project and receive a detailed quote.