Winter Welding Guide

Table of Contents > 1. Is Welding in Winter Hard?     1.1 How Does Cold Weather and Low Temperatures Affect Welding?     1.2 Is Welding in Cold Weather the Same as Cold Welding? 2. Tips for Welding in Cold Weather     1. Preheat the pieces to improve ductility     2. Use low-hydrogen filler metals     3. Store electrodes away from cold and moisture     4. Check and warm up equipment before you start     5. Adjust your technique for cold-weather welding     6. Provide a safe workplace     7. Dress in layers and protect extremities     8. Good practices for outdoor winter welding     9. Post-weld treatment 3. Final Thoughts 4. 🧐Winter Welding Guide FAQ

As winter slowly approaches, temperatures drop, which can negatively impact many aspects of life, including the quality of your welds. Welding at room temperature is a breeze, but issues often arise once the temperatures drop.

The key to welding in winter lies in understanding the central challenge: low temperatures. Low temperatures cause faster cooling, which can lead to cracks, and they can also affect your equipment, arc stability, and overall health.

To help you get the best results, regardless of the conditions, we compiled this winter welding guide. The guide includes essential tips to help you produce the highest-quality welds and stay safe in harsh winter conditions.

Winter Outdoor Welding Repair
Source: https://www.youtube.com/watch?v=tSr4lDP4abU

Is Welding in Winter Hard?

Welding in comfortable positions, with the warmth of your home shop or a garage, is often a breeze. But, welding in winter, especially outdoors in conditions such as low temperatures, snow, or ice, can severely impact the quality of your welds and your health.

Outdoor Stick Welding in Winter
Source: https://www.youtube.com/watch?v=N9mlrQ1aYDw

Although winter welding is often reserved for professionals, you might find yourself in need of a repair or two. The key to achieving the best results and keeping yourself safe lies in understanding the primary challenge: cold temperatures.

In general, most structural welding codes specify 0°F as the minimum ambient temperature for welding. A common rule of thumb is to avoid welding below this temperature. However, specific applications such as piping or pressure vessel making don't recommend welding in temperatures below 32°F.

Nonetheless, the ASME welding codes state that welding should not be done at temperatures below 50°F. Still, professionals in outdoor welding applications can produce sound welds at temperatures as low as -20°F, but only under highly controlled conditions.

Winter Outdoor Welding Pipeline
Photo by @cody_lally (TikTok)

How Does Cold Weather and Low Temperatures Affect Welding?

Low temperatures can negatively affect multiple aspects of welding. However, they have the most significant impact on the following:

• Ductility of the metal: As the temperatures drop, so does the metal's ductility. If you are unfamiliar, ductility refers to a material's ability to deform under stress without breaking. At lower temperatures, the metal's crystalline structure rearranges, making it stiffer. Lack of movement makes the metal more susceptible to cracking. A brittle structure combined with hydrogen can cause cold cracking, also known as hydrogen-induced cracking (HIC).

• Faster cooling: Cold temperatures can accelerate cooling within the joint. As the metal cools, it contracts. Rapid cooling can trigger rapid contractions, creating microscopic cracks. In cold weather, cracking can occur even in weldable materials such as mild steel.

• Welding equipment: Some equipment may also malfunction at extreme temperatures. However, more commonly, cold weather will affect arc stability, making it difficult to control and maintain. Additionally, electrodes with high hydrogen content can increase the risk of cracking at low temperatures.

• Your concentration and technique: Cold weather can impair concentration and reaction time. Bulky clothing can reduce your dexterity, and dressing too lightly may cause you to shiver, affecting your precision and technique. The key is to find clothes that provide good protection from sparks and heat, sound insulation, and retain agility as you work.

Outdoor Stick Welding in Cold Weather
Photo by @welderbuckllc (TikTok)

Is Welding in Cold Weather the Same as Cold Welding?

No, these are two completely different terms you should be aware of before considering welding. Welding in cold weather involves using popular arc welding methods, such as MIG, TIG, or Stick, to join metals at low temperatures, including winter and extreme cold.

Cold welding, on the other hand, is a solid-state welding method that joins metals without heat. It involves joining metals at high pressure without melting or fusing them. These methods are suitable for heat-sensitive metals that are prone to heat damage.

Cold Welding Metals In a Vacuum
Source: https://www.youtube.com/watch?v=pavp6dps6q0

Tips for Welding in Cold Weather

Now that you understand the science behind the challenges of cold-weather welding, it is time for practical tips to help you achieve the highest-quality results in cold weather and extreme environments. We can sort all winter welding tips into three categories:

• Material preparation and handling: preheating, electrode selection, equipment check and use, storing consumables.

• Adjusted technique: slower welding speed, proper gas coverage, proper parameters, and condensation prevention.

• Safety and protection: Layered equipment with proper protection, good lightning and ventilation, a safe environment, and practices.

Let's further explain each.

TIG Welding in Cold Weather
Source: https://www.youtube.com/watch?v=xSxtMKoADjI

1. Preheat the pieces to improve ductility

As noted above, cold weather can reduce the ductility of the metal. Each metal has a ductile-to-brittle transition temperature (DBTT). At this temperature, the ductility drops drastically. In most steels, the DBTT is around 32°F (0°C), so it is often not recommended to weld below this temperature.

However, you can reduce the risk of cracks when welding in cold weather by preheating the pieces. The correct preheat temperature depends on several factors, including ambient temperature, material thickness, material type, and code requirements.

Maximum interpass should not exceed 400°F to maintain hardness.
Source: https://www.thefabricator.com/

A general recommendation with preheat for basic carbon steel like A36 is 50°F for material under 3/4" thick, once the ambient temperature is below 50°F. Thicker steel requires a preheat of up to 150°F, but some codes don't recommend welding if the ambient temperature drops below 32°F.

Preheating will improve the ductility and reduce the stress that occurs once the high-temperature arc hits the surface. By reducing the temperature difference between the weld area and the surrounding metal, you reduce the risk of cracking.

You can preheat the pieces using a torch or an electric heating blanket. The goal is to heat the surface evenly to prevent uneven expansion, which can cause microcracks.

Preheating the Workpiece Before Welding in Cold Weather
Source: https://www.youtube.com/watch?v=tSr4lDP4abU&t

2. Use low-hydrogen filler metals

Hydrogen enters the metal from the atmosphere or from the filler metal during high-heat processes, such as welding. As the metal cools, hydrogen atoms diffuse into the structure.

If the structure is brittle (due to rapid cooling during cold weather or reduced ductility caused by cold metal), it absorbs more hydrogen atoms, forming gas pockets. These pockets create internal pressure, leading to cracks known as hydrogen-induced cracks or cold cracks.

Types of Hydrogen-Induced Cracks in Welds
Source: https://www.youtube.com/watch?v=tGs840ktEvA

To minimize the risk of cold cracks in winter welding, use the low-hydrogen electrodes, such as E7018. These contain very little hydrogen, reducing the risk of cracks during cold weather.

For industrial outdoor use, specialized electrodes are available for extreme weather conditions. For example, there are electrodes for low-temperature offshore welding applications, but you are less likely to use them as an everyday welder.

Offshore Stick Welding in Action
Source: https://www.youtube.com/shorts/FUGIVcnxdFs

3. Store electrodes away from cold and moisture

Low-hydrogen electrodes used in winter welding can be pretty challenging to handle. They usually come in a sealed package that protects the electrode from moisture. Temperature changes can cause condensation, increasing the amount of hydrogen, which you want to avoid.

To address this issue, you'll need to store and use electrodes properly. Store electrodes in a warm, moisture-free environment to avoid contamination. Low-hydrogen rods usually require a rod oven that keeps them warm and moisture-free.

Therefore, you should bake the low-hydrogen electrodes before using them in cold weather. Doing so removes moisture and hydrogen from electrodes that have already been exposed to the environment.

Bake E7018 Electrodes Before Welding in Cold Weather
Source: https://www.youtube.com/watch?v=cXF2j1TCNL4

4. Check and warm up equipment before you start

Cold can affect your equipment, specifically some electronics, leads, or hoses. Before you start welding in cold weather, especially in sub-zero temperatures, check if your equipment is designed for such use. For example, anything water-cooled is at risk of freezing, oil loses viscosity, and batteries die much faster in cold weather.

Although the issues are more common in harsh conditions, even cold weather can negatively affect arc stability and equipment performance. Therefore, let the machine acclimate to the given conditions before turning it on.

Before starting an arc, turn on the machine and let it reach operating temperature. If you are using a generator or an engine-driven welder, use winter-blend fuel. Check the filters for dust or snow buildup, which can reduce airflow.

Finally, check all leads, hoses, and cables. Low temperatures can make the rubber insulation brittle, exposing the wires or causing gas leaks. Therefore, be sure to check the leads for cracks or signs of damage.

Inspect all leads, hoses, and cables before welding in cold weather.
Source: https://www.youtube.com/watch?v=euiU1hH3MLk

5. Adjust your technique for cold-weather welding

Welding in a cold environment also requires adjustments to the welding technique. You'll have to adjust the speed, heat input, and torch manipulation to reduce the risk of cracking.

Stick Welding in Cold Weather
Source: https://www.youtube.com/shorts/0DXypU9Srs4

• Lower welding speed: Move the electrode more slowly across the joint to reduce cooling and provide more even heat input. Slower cooling and even heat in cold weather minimize the risk of cracking.

• Higher heat input: If needed, you can slightly increase the amperage to provide better arc stability and penetration. Higher heat will battle the low environmental temperatures, as long as you don't overdo it and cause burn-through. Overall, if the metal is too cold, you'll need a good preheat and more amperage. While the effect might be negligible on thin metals, it is highly noticeable on thicker pieces.

• Minimize weaving: Whenever possible, use straight, stringer beads to focus the heat and improve penetration tightly. Weaving the torch creates a broader heat-affected zone (HAZ) and results in some heat loss. In freezing temperatures, this loss can be critical in achieving full penetration.

Straight Bead Stick Welding Using E7018
Source: https://www.youtube.com/watch?v=o3tHaSNDT1Q

6. Provide a safe workplace

When welding indoors, make sure you still have a natural draft or ventilation to prevent toxic fume buildup. Although a draft can reduce heat in a garage or workshop, it can help you avoid fume exposure.

If you are working outdoors, make sure your workplace is protected from cold winds and drafts. Besides lowering the apparent temperature, winter winds can also promote rapid cooling in a welding joint. As mentioned earlier, fast cooling, along with other factors, contributes to the formation of cold cracks.

To address these issues, you can use windbreaks or use welding tents. These protective barriers will help you maintain a consistent temperature in the welding area. You can also use heaters to improve the temperature, making yourself more comfortable, and the welding heat more manageable.

Cold-Weather Welding
Photo by @thedeadoasis(TikTok)

7. Dress in layers and protect extremities

Welding in extreme temperatures can be quite a challenge for your body. Dressing heavily to protect yourself from the cold is not the only issue. You will still need enough protection from sparks and dexterity to manipulate the torch and move around the workplace.

That's why you should always dress in layers when welding in winter. Although the number of clothes may vary depending on the conditions, experts recommend using the following layers:

• Base layer: Underwear that will wick sweat away from your skin.

• Middle layer: Your primary heat insulation that will retain body heat and keep you warm in cold weather.

• Outer layer: Protective equipment such as a fire-resistant jacket, apron, and jeans. These will keep you safe from sparks, radiation, and heat created by the welding arc, and they are a must-have.

Keep in mind that the weather might not be severe enough to require all the layers. However, it is always better to bring extra clothes, as you can always take them off.

Remember to cover the extremities, as they radiate heat from the body. Use warm socks and boots for your feet, and a neck gaiter, liners, and a hood for your head. Wool is perfect for your feet, especially if you sweat a lot. Wool can hold a third of its weight in moisture before you start to feel "wet".

Winter Outdoor Stick Welding Process
Photo by @jhg_223 (TikTok)

8. Good practices for outdoor winter welding

If you have to spend an entire shift welding outside at low temperatures, you'll need a good set of habits to keep yourself protected. Here are several tips on how to stay warm:

Outdoor Winter Welding
Source: https://www.youtube.com/watch?v=euiU1hH3MLk

• Keep yourself dry: Moisture or dampness from sweating or melted snow increases the rate of heat loss from the body. Try to keep yourself dry throughout the day, and always bring extra clothes in case you get wet.

• Stay hydrated: Drink enough warm, sweetened fluids throughout the day. Cold weather and reduced fluid consumption during winter can have severe consequences for your health. Keep a thermos of your favorite hot beverage handy at all times. Remember that alcohol and caffeine can lead to dehydration, so you'll want to avoid them.

• Eat plenty of calories: During the winter, the body spends extra energy to keep you warm, in addition to the energy spent during welding. Therefore, don't skip a hearty hot meal at lunchtime, or bring an extra thermos of soup.

• Keep moving: The body generates heat as you move around. Staying in place can make you feel cold, so try to walk a bit after each weld. However, don't overdo it. Excessive movement leads to excessive heat and, therefore, sweating. Thus, try to find a balance.

• Take breaks: On extremely cold days, take regular breaks inside. But don't make them too long. Your body acclimates to the conditions, so you can feel much colder outside if you take long breaks inside, in the warmth.

9. Post-weld treatment

During and after welding, continuously monitor for cracking. As noted, cracks are the most common defect in winter welding, so regularly inspect your welds.

Source: https://www.boyiprototyping.com/sheet-metal-fabrication-guide/common-welding-defects/

If you notice any signs of cracking, immediately stop to address the issue. Preventing cracks from forming will save you a lot of time spent reworking the pieces.

The key to addressing the cracks often lies in controlled cooling. Welding is a thermal process, so it's only natural that temperature plays a role. The biggest thing is to watch the cooling rate to avoid reduced weld strength and cracks.

Rapid cooling caused by cold temperatures is the leading cause of cracks during winter welding. Therefore, you'll need post-weld heat treatment.

Post-weld treatment includes using insulating blankets to promote gradual cooling. These will ensure the welds cool gradually and help you avoid thermal and residual stresses, which can lead to cracking.

Post-Weld Heat Treatment
Source: https://www.youtube.com/watch?v=ZGnghmO35XE&t

Final Thoughts

Welding in cold weather presents unique challenges. Besides making you feel cold, low temperatures also affect your equipment, metal properties, and cooling rates.

The key to successful winter welding lies in understanding your greatest enemy: low temperatures. Low temperatures make you feel cold, reducing your concentration and ability to wield a torch. However, more importantly, they reduce the ductility of the metal and cool welds much faster, leading to thermal stress and cracking.

But, with some adjustments, you can successfully weld in winter. Remember to put on warm, protective clothing and check and warm up your equipment. Preheat the metal to avoid thermal stress and adjust the technique to provide even heat exposure. Finally, check for defects, and use post-weld heat treatment to allow gradual cooling.

Repair Welding Outdoors in Winter
Photo by @jeison.c_09 (TikTok)