Can You Weld Stainless Steel With A Gasless MIG Welder?

As an Amazon Associate, I Earn From Qualifying Purchases.

Stainless steel welding with a gasless MIG welder is something new to you if you are a beginner. But many expert personals in the welding community understand the effects of MIG weld in the absence of shielding gas. It creates massive spatters, mess, and poor weld that is not acceptable. I need the clear, pleasant, and attractive weld at stainless steel materials that didn't destroy its outlook.

Welding is not an easy process that anyone can use without experience. Yes, you can weld with different portable materials, but you need the proper guidelines. It is always better to use a suitable welding apparatus and technique according to weld material.

However, you may wonder about the query "Can You Weld Stainless Steel with A Gasless MIG Welder?" so here is my approach:

Yes, you can weld stainless steel with a gasless MIG welder but ensure that you have the cored wired. These wires don't require shielding gasses and provide perfect weld. Use proper wire diameter that ranges between 0.25 to 0.35 inches. The welder must have the negative torch and able to use the wire in MIG welding.

Here I will provide the complete guideline regarding MIG gasless welding for stainless steel materials so you can perform it ideally.

So let's dig into it.

Is MIG Welding Possible Without Gas?

You can weld stainless steel with a MIG welder, but you need to find self-shielding flux cored wire that doesn't require external gases.

Every welder knows about MIG welding and the purpose of shielding gas, but you are looking for the MIG with gasless weld. Keep in mind that it is challenging to perform MIG welding without shielding gas. It is a fact that no one can displace the oxygen from the air, so our workplace also has environmental oxygen. So, you are not working in a gasless atmosphere.

Here brings the idea of MIG welding with wires. It would help if you chose between the solid and flux-cored wires for stainless steel welding.  Every steel material has a different thickness, so select the wire according to some factors. Ensure that you have the right penetration profile, fusion, and spatter levels that affect the MIG welding with cables.

However, the flux-cored wires are best for MIG welding without gas. Flux-cored wires make it possible to weld the stainless-steel materials while controlling inert and reactive gases during welding.

It doesn't require the shielding gas for weld as it provides the perfect penetration in stainless steel materials, which is best for beginners.

How does gasless MIG welder work?

A gasless MIG welder is a special type of MIG welder that does not use gas to provide shielding and the arc. How it works is by having an electric power supply powering two hot electrodes, one wire electrode (-), and another metal electrode (+). The welding process starts with turning on the electricity at both ends under which you connect your workpiece being welded.

The machine will produce very high-frequency electric waves in order to ignite the electric fluctuation between these two points so that it can create its own magnetic field (in other words, cause them to be attracted together). This creates enough heat for melting metals like steel.

Once this happens, then stick them adjacent to each other where more electrons are exchanged from one point to another as well as the molten metal being attracted to the workpiece.

This is why I said "gasless" because the machine doesn't need gas for shielding or an arc, but you do still have a wire electrode and another metal electrode so that it can create its own magnetic field in order to melt metals like steel.

How this process works relies on electron exchange from one point to another as well as magnetism which creates heat; enough of it so that melting occurs - just without using gases like argon, helium, carbon dioxide, etc.

How To Weld Stainless Steel With A Gasless MIG Welder?

Gasless MIG welding is an easy and quick process than typical MIG welding. It provides the perfect weld with a covered electrode that depends on the slag system. Traditional welding produces a chemical reaction that causes the arc and a massive number of gasses. Shielding gases react with these gases and protect the molten melt.

However, the gasless MIG welder or the flux core wire has its core, providing a wide range of benefits during welding. So for gasless MIG welding for stainless steel material, you require appropriate equipment, steel thickness, and wire. All these choices help to use the machine and weld inappropriate results.


Flux core deoxidized the molten material and didn't produce gasses.

Hold molten material:

Instead, it creates a protective slug that helps stimulate the attractive welding beads and maintains the spot's molten material. So this holding mechanism improves the welding capacity to preserve the structure of welding material at the point and let it fix effectively.

MIG welding gasless technique mix the element alloys with metal and support its mechanical properties that are best for stainless-steel welding. So, it has better penetration and deposition rate than stainless steel weld when it has the better modification for welding.


After holding the molten stainless steel at the desired position, let it cool for appropriate time. after cooling, you will have the perfect weld.

Get the MIG welding machine and weld the stainless steel material with appropriate flux core wire, and you will have the perfect nice bed weld according to your choice.

What are the Advantages and disadvantages of using a gasless MIG welder?

I've noticed that a lot of people are switching to gasless MIG welders, which is understandable. It's not always easy to find a location for propane tanks and it can be hard to carry around the bulky tanks. But there are some disadvantages as well! Let me tell you about them so you know what you're getting into before making your decision.

Advantages of using a gasless MIG welder

One of the gasless MIG welder main advantages is its ability to weld stainless steel. A gasless MIG welder is not limited to a single material, so it can be used on various types of metals and non-metals with no problem.

Gasless MIG welding also has the advantage of being able to do a variety of different metal thicknesses without any problems or additional equipment needed. This means that you are not restricted in your materials by having one type of gas available for each specific wire gauge size.

A gasless MIG welder does have some disadvantages though - while they are capable of working continuously like a traditional setup, there is still risk associated with using them due to their need for shielding gases as well as an increased chance at arc flashes since they produce more heat.

Disadvantages of using a gasless MIG welder

The main disadvantage of using a gasless MIG welder is that it's more expensive than a standard MIG welder and you need to purchase an additional wire feeder. If you plan on welding stainless steel with your gasless MIG welder, the wires will oxidize which causes them to deteriorate quickly, so you'll have to change them often.

There are also disadvantages if using this type of welders for aluminum or many other types of metals as well because they don't like being interrupted by high currents and can be damaged easily by too much heat.

You must use flux-cored (FCAW) wire when trying to weld some materials such as copper alloys- even though these kinds of wires might not last long in comparison with those used for gasless MIG welding that is typically only made of stainless steel.

In conclusion, gasless MIG welders are a great option for welding materials that need to be free from the taint of ozone and other gases. However, these types of welder might not work well with some metal alloys because they're more expensive than standard MIG welders and you have to change the cords often depending on what material it is that's being worked on.

And while this type of welder can't use aluminum or many other metals- there are some limitations (depending on where you live) in using them due to regulations so make sure you check those out before purchasing any equipment! The good news about flux-cored wire though is that they don't oxidize as quickly and typically don't need to be replaced nearly as often- so they're a better option for some materials.

Gasless Stainless-Steel MIG Welding Wire Size

MIG welding wire size is the key for gasless welding techniques. Every stainless-steel thickness requires a different wire size according to its capacity. Therefore, keep in mind that you must choose every factor like equipment, wire size, and steel thickness as all of them correlate to provide the appropriate welding results.

Here is the proper guide that helps you select the wire size according to your MIG gasless welding factors.

  • For thin material, 0.24 inches wire is best. This wire size is suitable for the 24-, 22-, 8- and 20-gauge thickness of the steel.
  • 0.35 inches of MIG gasless wire is best for different thickness terms.
  • According to the machine deposition rate, if you select the wire size,choose the 0.30 inches of wire.
  • For thicker materials like 5/16, ¼, and 3/8 inches, you can select the 0.45 inches diameter. This wire size provides a nice beaded weld at a suitable thickness.

Moreover, the wore diameter is also linked with the voltage input of the machine. For example, a MIG welder has 230 V to run the 0.35 inches wire diameter effectively. However, no matter the size of the flux core wire, It has enough shield to melt the metal and weld it with excellent results.

The fact that ticker welding material requires higher voltage must have powerful machines for thicker wire sizes. The amperage requirement of the device is also high for wider wire sizes.

Stainless Steel Flux Core Welding (Gasless MIG Welder) Settings

Gasless MIG welders have different settings than the traditional MIG welder with gas. First of all, you need to confirm that you have the gasless welding machine by checking it from its manual or package. The gas MIG welder requires the Tri-Mix cylinder that is not suitable for stainless steel welding.

Please choose the appropriate flux core wire and set it with the machine. Ensure that you attach it with the negative terminal of the device. Now set its suitable amperage and current voltage to support the wire penetration in stainless steel thickness.

Set all these three factors and start welding the stainless steel material. Ensure that you wear a protective mask. It doesn't have splatters, but it produces smoke during the procedure. So protection is always better than cure.

Reasons To Buy Gasless MIG Welder

Now you have the proper guideline to use the MIG gasless welder. But some of us may have confusion in mind. So they need some authentic reasons to buy a gasless MIG welder that is perfect for stainless steel material.

You should know some reasons before buying the MIG welder, so you have the suitable apparatus according to the welding material.

01. When you need to weld stainless steel outside?

The gasless MIG welder uses the flux core wire to produce the protective vapor that many of us require for outside welding of stainless steel materials. According to my experience, it is a durable option for outdoor use as it doesn't risk contamination. If typical external welding gets contaminated with water, then it causes lower quality and weaker welds.

A gasless MIG welder doesn't have any effect from the wind. However, the traditional MIG welding has protective gases that work best for inside stainless steel products. But the outside environment is prone to contamination from wind elements.

It provides robust welding at joints that didn't break or damage with a healthy environment. So prefer Gasless MIG welding for outer stainless steel material and get solid and bubble-free, durable weld.

02. There’s the cost of a gas setup

Gasless MIG steel welding doesn't require the gas setup that causes lots of cost in traditional welding. However, keep in mind that gas MIG welding requires inert or reactive gasses that are expensive. So it would help if you put a lot of cost into setting up the gas around the welding area.

However gasless welding technique only requires the flux core wire that is not expensive. You only need to buy a perfect MIG welder with appropriate flux core wore, and that is pretty much fine for stainless steel welding. It is not wise to put extra effort and cost to weld the stainless steel material and get poor weld.

03. What if you’re only welding stainless steel sometimes?

Sometimes I have pure stainless steel material for welding, but some materials mix other metals. So it is the point of thinking for the beginners who don't have much knowledge regarding welding or gasless welding.

So don't think of any other option as there is no better choice than the gasless stainless steel welding. It has the flux core wire according to the thickness of the material, and you will choose the suitable amperage and current. The right combination can penetrate any material and provide an excellent weld.

If you also have the mix metal materials with stainless steel composition, prefer using the gasless MIG welder than any other technique.

04. Sourcing Tri-Mix in small cylinder sizes is tricky

Traditional MIG welding requires a mixture of inert gasses that is always tricky. In the beginning, no one is an expert in the weld, so you need to have the appropriate welding technique. However, MIG has the Tri Mix of inert gasses. It is costly and tricky to handle at the time of weld.

Keep in mind that Tri-Mix of gasses has the risk of many damages like an explosion, the production of dangerous fumes, and many more. So try to avoid it and choose the suitable flux core wired gasless welding when you have the stainless steel welding material.

05. Do you have the space to store a Tri Mix cylinder?

Large welding areas are always dense with many other materials like raw material, welders, transferring material from one place to another, and many more. So they usually don't have the space to store Tri-Mix cylinders of gasses for MIG welding. On the other hand, small welding areas are out of space as they need to maintain every operation to a limited extent. So they don't have a place to store and adjust Tri-Mix cylinders for a long time.

So when you don't have the space to store Tri-Mix cylinders, it is advisable to get the gasless MIG welder, which is a suitable option for condensed small spaces. It requires not only less space but also provides a nice stainless steel weld.

Who can benefit from using a gasless MIG welder?

A gasless MIG welder is a special type of welding machine that uses a non-consumable shielding gas.

This type of welder is used by professionals in many industries, such as those working with stainless steel and aluminum--two materials that are not easily welded using conventional MIG or TIG processes.

Stainless steel can be difficult to work with because the metal is often too hot during welding when it's being worked on, so it needs protection from heat while the worker does their job. The shielding gas flows through the material to protect it from these high temperatures.

Aluminum requires less heating for successful welding than other metals do, but this process also relies heavily on heavy amounts of aluminum oxide fumes (also known as 'aluminum fume') to prevent melting and burning at higher welders that give aluminum a very strong resistance to corrosion.

A gasless MIG welder is an excellent option for professionals looking to weld these or similar metals because it offers the level of protection and shielding from high heats that stainless steel and aluminum welding needs, while still being capable of working on other materials like steel and copper without any problems at all.

While this type of welder can be expensive up-front compared with standard MIG types, many users find they have significantly lower maintenance costs in the long term when using one as their primary machine because its lifespan is so much longer than traditional machines--which means less time spent replacing parts constantly over the course of years.


So by summing up the above discussion, it is clear that gasless MIG weld is perfect for stainless steel material. It requires a suitable flux core wire size that penetrates well at the given amperage and current welder. Every good thing has some drawbacks, so you may notice the smoke is not a big issue compared to managing the Tri-Mix gas cylinder during the weld.

Keep in mind that every MIG welding machine is suitable for the flux core and solid wires. But you need to set the polarity of the welding machine according to the wire size. Stainless steel material thickness, wire penetration capacity, and polarity are the main three factors correlated with each other. So you need to set these with a suitable combination and get a nice weld at stainless steel material.

Moreover, it is advisable to check the machine capacity by reading its manual and supporting the gasless welding.

I hope this guide will help you a lot in gasless stainless steel welding, and you will have the best results in the end.


Are Gasless MIG Welders Any Good?

Gasless MIG welders are good as they provide an excellent penetration rate. It also provides an impressive strength full weld, but mostly it depends on the machine and technique used. Some gasless MIG welders work best for thin materials, and some work best for thicker materials. So choose appliances according to penetration rate and thickness.

Can you weld stainless steel with normal MIG wire?

Yes, it is possible to weld the stainless steel material with regular MIG wire. Stainless steel has chromium and Nickel to provide it a rust-resistant and shiny look. However, standard MIG wire causes rust at the junction, and you may not like the results.

Can I use the mild steel wire to weld stainless steel?

Mild steel wires are only suitable for thin steel. So it can only weld the lighter stainless steel materials, and you can not get the appropriate weld results by using it on thick stainless steel plates.

Last Updated on July 10, 2021 by weldinghubs

Leave a Comment

Home » Welding Machine » Can You Weld Stainless Steel With A Gasless MIG Welder?