The cost to weld aluminum averages about $14 to $22 per pound. The type of metal factors into the overall cost of any welding project due to the cost of the materials and the expertise required to work with it.
Some of the most common metals used by welders include:
Magnesium alloy: $7–$16 per pound
Low-carbon steel: $11–$12 per pound
Stainless steel: $13–$15 per pound
Copper/brass: $24–$29 per pound
Cast iron: $38–$79 per pound
Titanium: $60–$85 per pound
Choosing the right metal fabricator for your project begins with research. Find a reputable fabrication company by searching for reputable contractors in your area, and then reviewing photos of their previous work, customer reviews, and photos of the company’s workshop.
Once you’ve narrowed down the list, contact the companies to ask about the types of metal fabrication projects they specialize and inquire about guarantees and warranties on workmanship. You should also ensure the company uses high-quality material, and ask about the schedule and turnaround time for your proposed project.
Welders use a variety of methods in their trade. Different types of welding are better suited for different purposes and contexts. For example, stick welding is a versatile form suitable for most metals and alloys.
The most common types of welding include:
Stick welding: $100–$1,000
Metal Inert Gas (MIG) welding: $250 and up
Tungsten Inert Gas (TIG) welding: $250 and up
Gas welding: $150 and up
Forge welding: $15–$25 per hour
While a high-speed circular saw will cut through metal, and even cut through multiple sheets at once, the fast-spinning saw blades create a lot of heat. This heat can damage paint and other protective coatings, leading to serious problems like rust over time. The cost to paint a metal roof again to avoid this damage is typically an additional $0.50 to $1 per square foot.
It will likely take an experienced pro less than an hour to install a ground rod, which is another reason why letting them handle the job is such a good idea. Safety concerns aside, it would likely take you much longer to install a ground rod if you decided to take this one as a DIY job.
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