How Much Does Welding Metal Cost for Various Types of Projects?

Typical Range:

$121 - $472

Find out how much your project will cost.

Cost data is based on actual project costs as reported by 826 HomeAdvisor members. Embed this data

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  • Homeowners use HomeAdvisor to find pros for home projects.
  • When their projects are done, they fill out a short cost survey.
  • We compile the data and report costs back to you.

Published January 10, 2022

Written by HomeAdvisor.

The average cost of a welding project is $475. Depending on the project and the type of metal, costs can be as low as $50 or as high as $900. Additional factors that affect the cost include the type of metal wire or rods used as filler for the project and the type of welding required.

Average Cost to Weld Metal

Average Cost

$475

High Cost

$900

Low Cost

$50

Metal Welding Prices

The prices for metal welding materials range from $100 to $230. This cost includes the base metal, the flux or gas, the wire, and sandpaper. This price does not account for the cost of a small project or repair, where you only use a fraction of the material. In such cases, you (or the pro) would still need to purchase larger quantities of the necessary supplies.

Metal Welding Costs

Nationally, the average hourly cost to hire a welder is $65 to $125. Remember, too, that these pros have a minimum service charge to cover overheads and transport. Therefore, if patching a broken garden chair only takes 15 minutes, you'll still pay the full minimum fee, which is usually one or two hours of labor.

Metal Welding Costs By Project

The time required and the amount of materials used varies significantly based on the welding project. Therefore, naturally, the total project cost varies, too. Let's take a look at some common welding projects and their typical costs.

Project

Cost Range (All-In)

Average Cost (All-In)

Metal furniture repair

$35—$100

$67.50

Pipe repair

$120—$160

$140

Small gates

$550—$750

$650

Fencing

$1,200—$1,800

$1,500

Fabricated sheet metal welding

$700—$2,500

$1,600

Metal Furniture Repair

Metal furniture repair, such as garden seating and outdoor dining sets, is a common welding project that costs between $35 and $100. Patching a couple of leg braces on a garden chair comes in at the low end of the budget, while fixing a large garden bench or dining table will cost closer to $100.

Pipe Repair

Pipe repair costs $120 to $160 and is one of the most common residential welding repair projects. The type of pipe, the extent of the damage, the location of the pipework, and the type of metal determine how much you can expect to pay.

Small Gates

Small gates, like narrow garden gates or baby gates, cost around $550 to $750, all in. This price includes the cost of the base metal, the welding, cutting, grinding, construction, finishing, and installation of the new gate.

Fencing

Fence welding projects typically cost $1,200 to $1,800. This cost includes the base materials plus construction and installation like small gates. The price you pay for fencing depends on the type of metal you're using, the height and length of the fence, and any ornate detailing you require.

If you're only repairing a fence, you'll pay considerably less. For example, the cost to repair a wrought iron fence is $250 to $750.

Fabricated Sheet Metal Welding

Fabricated sheet metal welding costs $750 to $2,500, although you can pay as little as $100 for a simple patch or seam repair. If you're creating a custom outbuilding, the cost could be as high as $6,000.

The cost range here includes the fabricated sheet metal and the construction of the building, alongside the welding. In sheet metal fabrication, welding is used to join metal panels and reinforce joists and stabilize frames.

Metal Welding Costs by Type of Metal

Metal

Average Range Cost (Per Pound)

Average Cost (Per Pound)

Magnesium alloy

$7—$16

$11

Low-carbon steel

$10.50—$11.50

$11

Stainless steel

$13—$15

$14

Aluminum

$14—$22

$18

Copper/brass

$24—$29

$26

Cast iron

$38—$79

$58

Titanium

$60—$85

$72

Magnesium Alloy

Magnesium alloy costs around $11 per pound and is suitable for AC TIG welding. It's lightweight, easy to cast, and is vibration-absorbing.

Low-Carbon Steel

Low-carbon steel, or mild steel, costs around $11 per pound and is a popular choice because of its ease of welding. This versatile metal alloy is highly cost-effective, doesn't shrink much, is easy to work with, and is suitable for all types of welding apart from AC TIG.

Stainless Steel

Stainless steel typically costs $14 per pound and is prized for its ease of use and corrosion resistance. However, it's important to know what you're working with because martensitic-grade stainless steel has a habit of cracking, so it isn't the best choice for welding. Instead, stick with ferritic and austenitic grades. Stainless steel works well with all types of welding, apart from AC TIG.

Aluminum

Aluminum costs approximately $18 per pound. It's a little more challenging to work with than steel, but still very versatile, corrosion-resistant, and lightweight. The challenge lies in the higher rate of shrinkage, which can result in craters and cracks unless care is taken during the welding process. Aluminum is best for stick, MIG, and AC TIG welding.

Copper/Brass

Copper and brass alloys cost around $26 per pound and are popular because of their thermal and electrical conductivity, high level of wear resistance, and corrosion resistance.

While high-quality copper and brass are reasonably easy to work with, some alloy mixes, including cheaper alloys with impurities, can easily crack, form craters, oxidize, or corrode. Lower-grade alloys also have weaker electrical and thermal conductivity. Copper and brass are best suited to DC TIG welding.

Cast Iron

Cast iron costs roughly $58 per pound and, while expensive, if handled correctly, produces strong, durable welds. However, it does require a high degree of skill because of the high carbon and silicon content.

If it isn't pre-heated, or the temperature changes are too aggressive and rapid, it can crack or result in craters. Plus, the welds won't be as strong. Cast iron is suitable for stick welding.

Titanium

Titanium costs approximately $72 per pound and requires the skills of a master welder. It's a highly effective, durable option but does require extra equipment and full coverage with shielding gas to prevent oxidation. Titanium is suitable for DC TIG welding.

Welding Cost Factors

Aside from the type of metal and project, the accessibility of an area and the difficulty of the task impact the total cost. The type of welding can also affect the price, but the type of welding is determined by the project and the type of metal, as not all types of welding can be used for all metals or projects.

Stick Welding

Previously known as shielded metal arc welding, stick welding uses extreme heat to melt two separate pieces of metal together. Sometimes a third metal is included to add strength. The metals become strong as they cool, and no bottles of gas are required. It's best done outside, as there is a lot of smoke and splatter. Note that pros cannot use sticks with metals thinner than an 18 gauge.

Metal Inert Gas (MIG) Welding

Metal inert gas welding, or MIG welding, is an arc welding process that uses a solid wire electrode. This wire is heated and fed into a weld pool from a welding gun. The two base metals are melted together. Alongside the electrode, the gun feeds a shielding gas that protects the weld pool from airborne contaminants and prevents oxidation.

Tungsten Inert Gas (TIG) Welding

Tungsten Inert Gas welding, or TIG welding, uses a similar arc welding process to MIG welding. TIG welding uses a metal rod made of tungsten to weld two disparate pieces of metal together. A foot pedal controls the heat of the arc. Unlike MIG, which can use a variety of shielding gases, TIG welding projects require 100% argon gas as its shielding component.

Gas Welding

Gas welding is one of the oldest types of welding. A flammable gas, such as acetylene and oxygen, is super-heated to weld two pieces of metal together. It has a huge range of applications and is one of the most common welding processes.

Forge Welding

Forge welding involves heating two pieces of metal, then using force, like hammering, to join them together. This type is a form of blacksmithing and is among the oldest types of welding.

DIY vs. Hiring a Welding Pro

It's wise to leave the welding to the pros. Sure, you can save on labor, but the cost of buying all the equipment, the safety gear, and the supplies you need overrides anything you might have saved.

Welding is dangerous unless you know what you're doing. Remember, you're using extreme heat to join metal. Plus, some of the substances you may come into contact with pose significant health risks. If you've got something that needs welding, hire a local welder.

FAQs About Welding Metal

What type of metal is used for welding?

Pros can use a range of metals for welding. The most common are:

  • Low-carbon steel

  • Stainless steel

  • Aluminum

  • Copper/brass

  • Cast iron

  • Magnesium alloy

  • Titanium

What is the easiest way to weld metal?

Pros generally consider MIG welding to be the most accessible type of welding to learn for beginners.

What are the 5 types of welding?

The five types of welding are

  • Stick welding

  • Metal Inert Gas welding (MIG)

  • Tungsten Inert Gas welding (TIG)

  • Gas welding

  • Forge welding

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