Stick Welding Hardened Steel

As the name suggests, hardened steel is a type of steel or high-carbon steel that has undergone extreme heating to make the metal strong.

But is it possible to stick weld hardened steel, and if it is, how is it to be done?

Let’s figure it out.

Can You Stick Weld Hardened Steel?

Can You Stick Weld Hardened Steel

It doesn’t matter whether it is hardened or mild steel; any steel can be welded. However, the situation with welding hardened steel is a little different.

Because with it, you’ll have to use extreme heat in all forms of metal welding.

Without that level of heat, you won’t be able to join those metal parts and keep them together. Moreover, it should also be noted that the hardened steel, after welding, must not lose its original hardness.

A welder must treat it again to help the hardened steel regain its original shape. Besides, one can also change the mode of heating or welding if a specified mean is not providing enough heat, which is required.

Which Welding Rod Is Used For Hardened Steel?

Which Welding Rod Is Used For Hardened Steel

Working with, using, or applying any mild-duty rod while welding joints of hardened steel will not be beneficial.

Because it will not be able to produce the required heat needed to melt the available hardened steel and weld it, in that case, you should use the right rod with the welding stick to make it possible.

Here, you can use two rods depending on the intensity of hardness. One can use 7018 rods with a tensile strength of 70,000 Psi, one of the most versatile welding rods for welding hardened steel.

Its prime use is for low and moderate-carbon steel, but you can also apply this rod on hardened steel.

Besides, one can also use the 7024 rod, which is even more robust and better than the 7018. Most welders recommend using 7024 when they need to weld hardened steel.

How Do You Stick Welding Hardened Steel? (Step By Step Guide)

The welding process to stick weld hardened steel could differ depending on who is welding it and how much experience that person has in this field.

But the most common steps a professional welder or a DIY welder goes through are described as follows. Please have a look.

Caution: It could be a little tricky and complicated to weld hardened steel because that extreme heat may affect the metal to go a little brittle. In that case, one must always be cautious about using the proper heating and cooling methods to treat that metal.

Step 1: Joining Or Clamping the Hardened Steel Pieces Together

To achieve the best welding results of welding hardened steel, you must remember the most appropriate post-welding heat treatments.

Besides, choose only those welding joints that can efficiently distribute the stress on metal evenly.

To start with the welding process, be straightforward and bring together those pieces of hardened steel together. Make sure they don’t change their positions while welding.

Step 2: Mark On Welding Area

In this step, mark both sides of the desired welding area using some welding temperature crayons.

These will leave marks on the metal and usually melt when you let them through various temperatures. You can help yourself prevent overheating the hardened steel in this way.

Step 3: Preheating The Metal

In this step, you need to preheat the area you’d be welding with your stick welding machine and rod.

Do this for almost 3 to 5 minutes. When you’d warm the metal before its heating, it will be beneficial in preventing its crystalline structure from changing.

And this change comes when a confident and sudden amount of heat is applied to the steel.

Step 4: Start Welding

Finally, take that rod-equipped stick or gun in your hand, set the temperature reading on the machine, and start welding that hardened steel with the metal.

To create more substantial welding penetration, keep checking the temperature of hardened steel.

Step 5: Cold The Metal

Now, you need to cool down that welded metal after you have joined them together. One can use a fire blanket or something that would cool down the weld area slower.

What To Focus on When Stick Welding Hardened Steel?

Before you start stick welding hardened steel, it would be fine if you’d consult with any structural engineer.

Besides, keep in mind to use a welding helmet and gloves while you are welding. Moreover, welding machines are not recommended near any flammable materials.

Hardened Steel Stick Welding Common Mistake & How To Avoid Them?

Most people make the following mistakes while performing this type of welding. But one can also avoid them by taking proper precautions.

  • People or many welders perform welding where there is no source of fresh air. Never do that, and always perform welding in a vast space so that air clogging might not be a problem.
  • It would be beneficial to preheat the metal to avoid common structural problems that might happen during the welding process.
  • One must always be covered up and wear a helmet and goggles to keep their eyes protected. Don’t be a hero.
  • Wear heavy-duty gloves while holding the stick in your hand.
  • There can be some flammable materials near you that might result in rapid fire. Please avoid performing welding at such places or near such materials.
  • If you are not an expert in performing welding like this, don’t do it by yourself. Ask for an expert at that time.

Last Words

Finally, it’s easier to stick weld hardened steel if you do it adequately. One must consult with a professional welder or ask him to perform that duty.

Moreover, never try something like this yourself when you are not an expert.


What Happens If You Stick Weld Hardened Steel?

The process can be tricky at most times, which may result in changing the shape of the hardened steel. Therefore, one must use the right amount of heat and cooling methods in treating metal while welding.

Is Hardened Steel Harder To Weld?

Hardened steel is not really hard to weld. But one must use the right equipment and heat while performing this welding process.


  • James Smith

    This is James Smith, a Hobbyist welder, welding since my 15th birthday. My father was a professional welding mechanic at a garage and used to take me to garage. My love for welding started then and I learnt basics from my father. At my 15th, my father gifted me a stick welder and my journey to become a welder began. Gradually I accustomed to welding and mastered at tig welding.

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