Can You Weld Rusted Metal? The Answer Might Surprise You!

There’s nothing more annoying than seeing that orangey-brown rust on your metal belongings. Especially if you own something like a car or a fridge, which you only use occasionally. When left alone for too long, even the most unnoticeable household item can become prone to corrosion. It’s not uncommon to find rusted items at home and in industrial environments as well. But what do you do once you see that disgusting hue? What you need is a contractor who can tackle this problem for you once and for all—a welder! Welding is one of the easiest ways to repair rusted metal and make it look brand new again. So read on to know if you can weld rusted metal and how.

Can You Weld Rusted Metal

Rusted metal can be welded depending on the extent of the rust. There are some precautions that must be taken to ensure a successful weld. First, the metal must be cleaned of all dirt and debris. Next, you must ensure the surface is free of all moisture, which can cause the weld to crack. You may need to dry the surface with a hair dryer or heat gun. Once the surface is dry, you can begin welding.

How To Weld Rusted Metal

1. Determine the Type of Metal

Before you start welding, you need to know the type of metal that you’re dealing with. The type of metal can determine what the weld will look like. For example, stainless steel is more resistant than other metals to corrosion. As such, it doesn’t rust easily. So if you have something made of stainless steel, then a welding solution that works on stainless steel might not work too well on rusted materials. If your item is not stainless steel, then a different set of solutions might be required to repair it.

2. Decide on the Welding Method

Once you know what type of material your item is made out of, it’s time to decide which welding method you’re going to use to fix the rusted metal issue! There are several options available for repairing rusted items: plasma arc cutting (POC), gas tungsten arc welding (GTAW), and gas metal arc welding (MIG). Each technique has its own advantages and disadvantages. So it all depends on what suits your needs best! Let’s find out which one is best suited for repairing rusted items:

3. Clean Up

Before you start welding, it is vital to clean up the area. You can do this by using a wire brush or an abrasive sponge. Remove all the rust, dirt, and other debris from the item so that you can properly weld the surface of it.

4. Prepare Your Welding Goggles and Gloves

Before you start welding, make sure that you have a pair of welding goggles and gloves to protect yourself from fumes. The fumes are toxic, so make sure that you’re wearing proper safety gear when you do your job! Also, check if your gas mask is able to filter out harmful gases like carbon monoxide and hydrogen chloride as well! It’s always better to be safe than sorry—so wear protective gear when working with gas-based welding solutions! Once everything is ready, get started on fixing rusted metal!

5. Weld the Rusted Metal

Once you’re ready, it’s time to start welding! To do this, prepare your welding solution by mixing a little bit of flux with the gas in your tank. You can also use a flux brush to distribute it evenly across the surface of your rusted item. Then, you need to make sure that you have a good backup plan if things don’t go according to plan. Make sure that you have another set of materials and tools ready in case something goes wrong during the process! After all, you never know when things might go awry!

6. Wait for It to Cool Down

You will notice that rusted metal has a tendency of heating up when you weld it—so make sure that you wait until it cools down so that it doesn’t melt off! Once everything is cool enough, then remove your goggles and gloves and apply more flux on the surface so that welding is easier and more efficient! Now, just follow along with how I did this project here: How To Repair Rusted Metal With Welding Solution.

7. Clean Up Your Area

After the job is done, you will have to clean up your area. To do this, use a wire brush or an abrasive sponge and get rid of all the dirt and debris that you can. The last thing you want to do is to leave rust stains on your item! It’s time to get rid of it!

What Is The Best Way To Repair Rust?


The first thing you need to do is remove the existing rust from the metal. The easiest way to do this is by using a die grinder, which will take off the rust from the surface of the metal. If you don’t have access to a die grinder, you can use a pneumatic welder for this job. However, it’s advisable for you to rent a pneumatic welder instead of buying one because renting one gives you more flexibility in terms of time and cost.


Once you’ve removed the rust from your metal, it will probably look like this:

You may not want to leave the rusted part like that, as it might look ugly and old after all. So what should be next? You should use an abrasive on your rusted part to sand it down so that it looks clean and new again! You can either use an orbital sander or hand sandpaper (which is more efficient). Or if you’re looking for something more advanced yet cost-effective, take a look at our top picks for orbital sanders.

Metal Polishing

The next thing you should do is polish your rusted part using an organic solvent such as acetone or rubbing alcohol. This will remove any remaining scratches on your rusted metal, resulting in a shiny finish that looks brand new again! For more information about how to polish metal, check out this guide.


Once you’ve polished your rusted part, it’s time to weld it! If you don’t have access to a pneumatic welder, you can use a gas welder, which will work just as well. You should also use a filler metal such as steel wool or aluminum foil when welding rusted metal because the filler metal will fill any gaps in the weld and prevent it from rusting further.


Finally, once your rusted part has been welded, it’s time to paint it! You can either choose to paint it using enamel or paint-on primer, depending on what type of look you want for your rusted part. For more about painting metal, check out this guide.


After you’ve painted your rusted part, it’s time to give it a final coat of paint. You can either choose to paint it using enamel or a paint-on primer. For more information about how to paint metal, check out this guide.

Storing Your Rusted Part Safely

After you’ve fixed your rusted part, you might want to store it safely in your garage or shed until the next time you need it. This is because if the rust is not completely removed from the surface of the metal, rust will start forming again even if you keep the rusted part outside for a few years. If this happens, the rust will eventually destroy your car and make it unusable! So what should be done with rusted parts that have been fixed? You should take them to a car repair shop and have them restored professionally so that they look brand new again!


There’s nothing more annoying than seeing that orangey-brown rust on your metal belongings. Especially if you own something like a car or a fridge, which you only use occasionally. When left alone for too long, even the most unnoticeable household item can become prone to corrosion. To prevent this, you need to clean the rusted item and then apply a rust-prevention spray. You can also use baking soda or salt to clean rust off metal. If the rust has already set in, you can use one of the methods mentioned above to get rid of the rust. Once the rust is gone, you’ll need to apply a rust-prevention spray to keep it away for good.

Felix Hiett
Felix Hiett
Felix Hiett is a welding expert blogger who writes about welding and other related topics. He is also an experienced welder and has worked on a variety of projects.