Selecting the right filler metal to match a base material is key

to welding success.
Categories: Feature Stories
Date: Apr 10, 2009
Title: Key Criteria for Matching Filler Metals to Your Base Material
Selecting filler metals can be a difficult task, as there are a multitude of factors that contribute to the decision.
The available welding equipment, the necessary welding position, the joint design and the service environment
the final weld will encounter each need to be considered, as does the welding operators skill level.

But there are also some slightly more complicated
aspects to consider when determining how to match
filler metals to a given base material. The materials
chemical and mechanical properties, its shape and
thickness, and the welding procedures to which
welding operators must adhere are some factors
dictate filler metal choice. Carefully considering
each of these can help ease the selection and ensure
quality welds with fewer complications.
Consider the Material
In order to properly match a filler metal to a base
material, begin with the general properties of that
material. First, the selected filler metal must be
compatible with the chemical composition or alloy
of the base material. For example, welding on
ASTM A387/A387M, GradeP11 of chrome-moly
pipe requires a low alloy filler metal, typically an
AWSA5.XX, 1 % Cr-1/2% Mo product, while
welding on A36 steel requires a carbon steel
product, such as an AWS A5.XX, 70ksi tensile
strength carbon steel filler metal.
Secondly, consider the mechanical properties of the
base material. These properties, which are usually identified by ASTM or similar material standards, include
tensile and yield strength, as well as the elongation and toughness (CVN, or Charpy V-notch) properties. The
appropriate filler metal should possess similar mechanical properties to ensure the integrity of the final weld.
As a general rule, most applications require matching filler metal tensile or yield strength to that of the base
material as applicable to the design requirements. The term match here is in quotations, as the two strengths
are not exact. For example, A36 steel has minimum yield strength of 36 ksi, but there are no such low
strength filler metals available in the marketplace. Instead, this material would be matched with a filler metal
that offered the closest tensile and yield strength, such as an AWS A5.XX 70ksi tensile class filler metal,
which provides a weld deposit of 70 ksi minimum tensile strength and 58 ksi minimum yield strength.
In some cases, it may be desirable to undermatch the strength of the filler metal to the base material,
especially when making certain fillet welds or on an application requiring only partial joint penetration (PJP).
Undermatching can be more economical and may help minimize the residual stresses in the weldment.
Overmatching filler metal strength to a base materials strength is more controversial and is generally
discouraged, except in some instances where yielding in the base material is more desirable. An example is
spooled piping.
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Next, consider the base materials shape, thickness and general condition to help determine the appropriate
filler metal. For instance, a pipe-to-pipe application usually has a saddle joint design (found in TYK) and
would require a different diameter of filler metal and/or one with different weld position capabilities than a
plate application, due to the location and the depth of the joint design. A heavy plate weldment, on the other
hand, typically has a T-joint or butt joint and requires complete joint penetration (CJP) and backing. It may
use a larger diameter electrode at higher currents to increase penetration and production compared to TKY
pipe joints.
Another factor to consider is the thickness of the material to be welded, as some material thickness directly
affect the materials strength. Consider the strength of quenched and tempered steel, such as
A514/A514M-05. This material has a tensile strength of 110ksi to 130ksi, 100ksi minimum yield strength and
18% elongation when it is 2 -inches thick or less. When it is greater than this thickness (2 - to 6-inches
thick), its mechanical properties change. They are now approximately 100ksi to 130ksi tensile strength; 90ksi
minimum yield strength; and 16% elongation. The quench and tempering process is responsible for this
change, as the thicker material has a slower quench rate that results in lower minimum yield and tensile
strengths. As a result, this thicker material may require a lower strength filler metal.Similar differences in
mechanical properties occur with hot or cold rolled materials, such as mild steel, and those that are post-weld
heat treated (PWHT), case or through hardened, or normalized. In each instance, these material conditions
need to be considered when making a filler metal selection.
Another manufacturing process, cold rolling, creates a different material condition with higher strengths than
as-rolled AISI 1040, and therefore requires higher strength filler metal for welding it. It will also, because of its
higher strength and lower elongation properties, be more sensitive to cracking; the chosen filler metal and
welding procedure will need to accommodate for such vulnerability.
As a rule, choosing filler metals with low diffusible hydrogen levels offer the least amount of potential for
cracking in these higher strength and less ductile materials. Also, less ductile harder materials may require
higher pre-heat and interpass temperatures during welding.
What are the Requirements?
For certain applications, welding codes and specifications may determine filler metal selection, including the
type, diameter and strength. Under these codes and specifications, filler metals must provide specific chemical
and/or mechanical properties, CVN toughness, temper embrittlement conditions, hardness or other similar
requirements.
The type of application, specifically whether it is for production or repair, factors into the filler metal (and
welding process) decision, as does the desired finished condition of the weld. In a repair situation, base
materials that have been in service and need repair often have dirt, oil, rust or other contaminants on their
surface. Additionally, the weld repair area may be or become highly restrained, requiring a filler metal with
maximum ductility, along with unique welding techniques to prevent weld and base metal failure after the
repair.
In addition, the physical location of a repair application dictates the welding process and the filler metal
capable of the welding positions needed to repair the base material. Take, for instance, a company that needs
to make a weld repair on a machine tool base, but does not want (or cannot) move it from its position on the
facility floor. Such repairs may require careful attention to pre-heat and interpass temperatures to prevent the
base material from expanding in its current location. Specifically, these temperatures must remain extremely
low and the filler metal must be capable of providing adequate strength and ductility under these conditions.
Conversely, in a production situation this same type of material may require elevated pre-heat and interpass
temperatures, a different welding position and processand a completely different filler metal. For example,
whereas the repair of a large hydraulic press fabricated from heavy sections of low-strength carbon steel, such
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as ASTM A36, may require a carbon steel SMAW electrode, the production of that same press could use
FCAW, GMAW, SAW filler metals. This is because the repair application may not allow for localized
pre-heating, but the production of the press does; it will also allow for different interpass temperatures.
Next, filler metal selection will depend on whether a material will be welded to itself or another type or
strength of material. Similar strength and type materials require a filler metal that has the same matching
tensile and/or yield strength. As an example, to weld two pieces of A514 steel together, a 110 ksi tensile
strength filler metal would be appropriate.
However, when welding dissimilar strength base materials, such as a piece of A514 steel to a piece of A36, the
variables dictating filler metal selection change. That is because when welding a higher strength base material
to one that has lower strength properties, the filler metal strength only needs to meet the mechanical
requirements of the lower strength material. For example, a 70 ksi tensile strength filler metal with 58 ksi yield
that matches the A36 material mechanical requirements (36 ksi yield strength) would provide adequate
strength when joined to A514 base material.
Many structural steel applications weldments are used in the as-welded condition, meaning the final weld is
acceptable for service after passing inspection; no further post-weld heat treatment is necessary. In this
situation, matching the filler metal to the base metal via strength and/or chemistry requirements will suffice.
In more critical applications, however, post-weld heat treating (PWHT) may be required and this directly
affects filler metal selection. Such a situation is common in pressure vessel and pressure tanker rail car
welding applications. When welding on certain vessel materials for these applications, the final weld may
require PWHT to improve impact or toughness properties and/or reduce any residual stresses in the weldment
that could lead to premature failure. AWS A5.XX filler metals for these applications are appropriate and are
readily available in the market place.
Applications requiring welds that need to be quenched and tempered, case hardened or normalized and
tempered, will use filler metals capable of maintaining their chemical and mechanical properties after such
post-weld treatments. These products, however, may be more difficult to obtain, as they must be specially
alloyed with additional elements to provide properties compatible to the base material.
Ultimately, if considering each of these criteria still leaves doubt as to matching a filler metal to a particular
base material, contact a trusted welding distributor or filler metal manufacturer for assistance. Filler metal
selection is absolutely critical to maintaining the integrity of the final weldment regardless of how simple or
complex the applicationtaking the time to make the right match is worthwhile.
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