How to Remove Welding: (Step by Step Guide)

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Welding is a process that joins metal parts together by melting the surfaces to be joined and then cooling them in such a way as to make them adhere. It's an important skill for any welder, but it can also be difficult to get rid of.

Fortunately, there are many ways that welders can remove welding without damaging their work or themselves.

So, how to remove welding? The best way to undo a weld depends on the type of welding being removed. Plasma cutting, torch cutting, grinding, or circular saws work well for some types while drills and oxy-acetylene torches are better at removing others.

It is a common misconception that welding is permanent. Welding can be removed, but the process will depend on what type of weld was used and how long ago it was done.

This article will provide professional tips on how to remove Welding so you know just what to do.

It is not uncommon for people to want to remove welds from metal. There are two methods to remove welds that include:

01. Thermal Methods

These are one of the many ways to undo welds. There are a variety of different thermal methods that can be used in order to cut through metal.

The most common type is oxy-acetylene torches which use flames and heat to cut through metal. Another form of thermal method is plasma cutting, which uses an electric arc between two electrodes and creates a jet of high-temperature, ionized gas that cuts through steel or other metals with ease.

A) Oxy-acetylene Torch Cutting

The oxy-acetylene torch is one of the most common tools in industry. It's used to cut, weld and braze metals together at very high temperatures (about 3500 degrees Celsius).

Most people use it for cutting or welding metal parts that are too thick or heavy to be done with other methods. The equipment is also cheaper, more portable, and can be used on larger and different kinds of metals.

The acetylene torches combine acetylene with oxygen to produce flames at very high temperatures which makes this method a little more dangerous than others.

Cutting with an oxy-acetylene torch can be difficult and time consuming.

Oxy-fuel cutting is a process that requires precision, patience, and skill.

Here's how to cut with an oxy-acetylene torch in 4 easy steps!

Step-01: Make sure you have the right equipment for your project (hoses, clamps, fuel tanks).

Step-02: Connect your hoses to the appropriate ports on the torches.

Step-03: Turn on both torches by turning them clockwise until they are fully engaged.

Step-04: Adjust the distance between your flame and material by moving it closer or farther away from the material being cut.

Step-05: Cut through metal using a slow steady pull while maintaining proper coupling distance.

B) Plasma Cutting

Plasma cutting is a process that involves cutting through electrical conductors with the help of an accelerated jet of hot plasma. With the help of direct current, an arc can be created, the temperature of which can reach up to 20,000 degrees Celsius.

The heat is generated by the high-pressure airflow that comes out of the small nozzle. Plasma cutting can be beneficial in terms of its cutting speed, since they are about five times faster than manual torches and can cut through a wide range of material thicknesses so any deep welds might also be undone.

When cutting with a plasma cutter, you should have the following equipment on hand:

  • Safety glasses (shade number five),
  • Respirator that can filter out vapors, fumes and dust particles.
  • Gloves for protection from heat or burns.
  • Plasma Cutter

Now, I'm going to show you some steps about how to cut with a plasma cutter.

Step-01: Set up your material on a sturdy surface. The surface should be metal or concrete.

Step-02: Measure the sheet metal and mark it where you want to cut.

Step-03: Compress air in tank and attach regulator to tank valve. Open valve and allow air into the cutting head. The blade needs about 50 psi of pre-cut pressure for safety precaution, but ideally the head should be fully pressurized before beginning work.

Step-04: Connect your torches together by placing the nozzle through a hole in the nozzle support on the cutting head. Make sure you connect them at a 90 degree angle. 

Step-05: Open the tank valve and pressurize head so it has enough pressure (50 psi) of pre-cut pressure.

Step-06: Mark where you want the cut on material surface or line up sheet metal if given space.

Step-07: Press nozzle down onto marked area until sparks appear from work point that's being cut. Make sure to keep the nozzle in contact with metal surface and move it back and forth along cut line, not dragging the blade over an extended length of steel (you will use up your pre-cut pressure quickly).  

The best results are achieved by using cutting speed as follows: Steel - about 25-35 inch per minute. Aluminum - about 20-30 inch per minute.

Step-08: To ensure your cuts have a proper depth you need to set up this equipment first: Acetylene hose (usually green), regulator with tank valve, cutting torch nozzle support bar and notch in handle for hose connection, oxyacetylene tube from head assembly to torch body including emergency stop button on valves at both ends.

Step-09: The three most important factors affecting how your cut will turn out are as follows. Your tips must be in good condition so they don't melt down while working. You need to make sure your pre-cut pressure is enough (it should be about 50 psi). Lastly, work points must have a good seal so the gas does not escape. 

That's it. I hope this article helped you understand how to cut with a plasma cutter. 

02. Mechanical Weld Remove Methods

In mechanical removal techniques, there is no heat involved but rather physical force applied manually by either drilling into the sheets themselves or using some kind of saws.

There are a few techniques you can choose to employ depending on the kind of weld you are dealing with.

For example, spot-welded sheets are challenging to separate, and you often have to perform the separation process by drilling into the sheets themselves.

Sometimes, separating metals can be impossible without causing some damage to the base metals.

Mechanical processes usually involve some kind of manual force applied to the welds, and it is often impossible to remove all traces without damaging the material.

Mechanical processes are usually slower than thermal ones. However, they can sometimes be more effective when dealing with difficult welds like spot-welded sheets.

In the end, you should know that there is not a single right answer to removing mechanical welds without damaging your material because every situation and type of metal requires different approaches for the best results.

The following is a list of the different methods you can use to remove mechanical welds:

  • Drilling into spot-welded sheets and then cutting them apart with saws or blades.
  • Using abrasive tools like grinders, wire brushes, and sandpaper for light surface removal.

A) Remove a Weld with a Grinder

It is important to know how to remove a weld with a grinder in order to complete projects and fix things around the house. Grinders are often used for grinding down metal or stone surfaces, cutting away excess material, or even polishing up finished products.

The first step is going back and carefully removing any leftover traces of the original weld by either using an angle grinder’s wire wheel attachment (which removes metal quickly) or scoring it off with an abrasive disk attachment (which grinds through metal slowly). You may also want to use some type of safety gear such as gloves, goggles, and earmuffs during this process since the sparks can sometimes fly out and cause injury.

Depending on the material that needs to be removed, you may want to use a wire wheel attachment or an abrasive disk attachment for grinding down the weld. Wire wheels are used for removing rust and paint from metal surfaces, which is why they are often referred to as wire wheels. Abrasive disks, on the other hand, are used to grind through metal slowly in order to even down a rough metallic surface.

If you need to polish your project when it is done, using an abrasive disk attachment will help give a smooth finish to a piece of work since they have abrasive particles packed into them. They can also be used to burnish copper and brass, making them useful for polishing up precious metals.

This article will go over the steps needed for removing a weld with a grinder.

Tools needed to remove the welds:

  • Angle grinder.
  • R980 P Speedlok 80 grit disk.
  • 2SF unitized disc for finish work.
  • Ear defenders, safety glasses, gloves, and long trousers.

Here I will show you step by step process to remove weld with a grinder.

Step 1: place the disc firmly on your workmanship so that it will not fall down.

Step 2: turn the angle grinder on to 320 rpm and set its speed control knob to " slow ".

Step 3: take an angle grinder sanding disc and screw it into place, if there are any burrs on the edge of your workpiece grind them down first using a flat disk.

Step 4: place the grinder at a 30-degree angle in relation to the edge you want to grind down and start grinding slowly, as soon as you reach your desired shape turn off the grinder and remove it from its position.

Step 5: using a soft cloth, remove the excess metal on and around the edge.

Step 6: inspect your work area for any edges or sharp corners if there are any, you may need to continue grinding

Remove weld with grinder is a good way to finish welding because when you use angle grinder it is cut in a small place which makes it easy to clean and also to get a shiny finishing.

B) Break a Weld with a Band Saw or Hack Saw

A weld is a form of joining two pieces together with metal melted in between. Welds can be broken by using either a band saw or a hack saw, but there are some differences that you should know about before starting this process. A hack saw is better for smaller areas and curves while the band saw is better for thick metal. If you're not sure which one to use, it's best to use both!

Step-01: Get a band saw and/or hack saw (If you're not sure which one to use, it's best to use both!)

Step-02: Make sure there is enough room for the blade if using a hack saw

Step-03: Mark the cutting line on the weld with a piece of chalk or pencil

Step-04: Cut all way through with the hack saw or band shears at a 90-degree angle

Step-05: Drill a 1/8 inch hole about an inch away from where you think the cut will be placed in order to help break the weld apart

Step-06: Use cold chisels to chip away material until the desired shape is reached

Step-07: Use a grinder to smooth out the surface

Consider using a jigsaw, reciprocating saw, or rotary tool instead. For this kind of situation, we recommend using cold chisels with the rotary tool and chiseling around the area until it breaks apart or using a reciprocating saw in order to cut thick steel. If you don't have any of these tools, then use a band saw for thin metal and a hacksaw for thicker metal.

Step-08: Clean up weld residue.

Step-09: Apply rust preventative if needed (e.g. paint, sealant)

Why Do You Need To Remove A Weld?

Welds are normally removed because they are either damaged, require repair, or are an obstacle to an inspection. In other words, their reasons for removal can vary depending on the project requirements and safety protocols there are.

One common reason for weld removal is when a metal part will be used in an application where the presence of any heat-affected zone (HAZ) would cause extra work or present safety issues. Some HAZ can't be removed and that's why it needs to be avoided by following certain procedures like preheating, post welding age treatment, and specialized welding techniques.

The cutting process is destructive because metal is given up at the point the cut is made which may render the metal unusable after breaking processes are complete. Additional work to remaining edges before use might also need to remove residual weld material left behind as well as cleanout any debris from past repairs if applicable.

In addition, if the weld is removed and replaced with a new one there might be some distortion of metal near the cut line. This type of distortion or deformation can create weak points in a completed part that could lead to premature failure. Preheating before cutting along with post-welding age treatments are good ways of avoiding this problem.

Which Process is better for Remove Welding?

Grinding is often considered the best option if your goal is to have a new surface that matches the surrounding area. Grinding also leaves less material around the weld than cutting does, so it's usually more cost-effective.

If you are looking for a process that will provide for even cut lines on both sides of your weld joint, grinding provides this service at an affordable rate.

Furthermore, compared to other methods such as clipping, trimming, or cold chipping, grinding allows you to remove more metal in one go – which saves time and money.

You can use your grinder alone or put together a batch with chips and shaving coming from other power tools like drills and saws.

By contrast, cutting is a very effective process for removing welds. One of the significant advantages of using this method over-grinding is that it leaves less space between your new joint and the surrounding area.

Cutting has a few more disadvantages, however. It can be highly dangerous due to flying particles, sparks or in some cases flames. Furthermore, you will have to endure additional costs for providing adequate ventilation at the cutting site. The process can also be time-consuming if you are only removing a small weld.

As with any procedure, there is no one answer that works best in all situations. Therefore, businesses that need to remove welds will often choose various methods of reducing and eliminating all traces of welds after the process is complete.

The most important factor for determining which method you will use to finish removing an old weld is your budget. If your budget requires a lower investment in new equipment, then grinding may be the best option for you. On the other hand, if safety and efficiency are primary concerns, cutting would be a better choice to consider.


There are many reasons why you may need to remove a weld. If the weld is in your home or garage door, it can be difficult and time-consuming without the right tools. With this blog post, we hope to give some insight on how to best remove welding from various surfaces with different equipment and processes.  First off, what exactly does removing a weld mean? Removing a weld means that you're taking apart two pieces of metal that were once connected by heat so they no longer touch each other where there was originally contact. The process will vary depending on whether you want to go through several steps or just use an electric arc as quickly as possible for emergency purposes only.

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Last Updated on September 26, 2021 by weldinghubs

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