SPECIALTY

ALLOY

WELDING

James Kelly
Director of Technology
September, 2002

Heat Resistant Alloy Welding

Carbon Steel versus Stainless

Surface Preparation
Shielding Gases
Cold Cracking versus Hot Cracking
Distortion
Penetration
Fabrication Time
Welding Austenitic Alloys
Alloys Under 20% Nickel
Alloys Over 20% Nickel
10
Age Hardening Alloys

Martensitic Stainless

Copper and Copper-Nickel Alloys

Dissimilar Metal Welds

Welding Processes
11
Gas Metal Arc Welding
11
Flux Cored Arc Welding
13
Shielded Metal Arc Welding
14
Gas Tungsten Arc Welding
16
Plasma Arc Welding
17
Submerged Arc Welding
18
Resistance Welding
19

2
3
4
5
7
7
8
9

Weld Fillers
Suggested Weld Fillers
20
Guidelines for Dissimilar Metal Joints
21
Heat Resistant Weld Filler Chemistries
22
Heat Resistant Alloy Specifications, Base Metal
23
Weld Filler Specifications & Tradenames, American vs. German
24
Bolts
25
Weld Filler Consumption
2
6
References
2
7

Bulletin 200
James Kelly
Rolled Alloys 2001
Revised May 23, 2001. Issued March 10, 2001
Heat Resistant Alloy Welding is based on Rolled Alloys experience and information from
suppliers such as Avesta Welding AB and Sandvik AB. For additional copies of this pamphlet,
contact Marketing Services, FAX +1-734-847-3915
e-mail marketingservices@rolledalloys.com

To buy on-line, or for technical information on all Rolled Alloys products, log on to our new
website
www.rolledalloys.com

Disclaimer Clause: The information in this document represents Rolled Alloys experience and opinions,
and is believed to be reliable. However, this material is not intended as a substitute for competent
professional engineering assistance which is a requisite to any specific application. Rolled Alloys makes
no warranty and assumes no legal liability or responsibility for results to be
obtained in any particular situation, and shall not be liable for any direct, special or consequential
damages. This material is subject to revision without prior notice.

Welding heat resistant alloys is touched on in our Bulletin No. 115, and covered in
more detail in Bulletin Numbers 201 & 207 for RA330 , 202 for RA 253 MA, 209 for
RA 353 MA, 211 for RA alloy X, and Bulletin 120 for RA333 welding products.
Corrosion resistant alloy welding is discussed in Bulletins 203, for alloy AL-6XN, 205
for 20Cb-3 stainless and 1071 for RA2205 duplex stainless. These alloys are all
weldable but they do require more shop time, and a DIFFERENT approach than
stainless, or carbon steel.
A few important rules:
1. Make reinforced, stringer beads. Do not weave. Shallow fillet welds or
broad, flat weld beads tend to crack down the center as they solidify. Cover
or fill in craters, to prevent them from cracking.

2. Keep heat input low. Do not ever preheat, except to dry moisture off of the
metal. Keep the temperature of the metal between weld passes low, below
212F (100C).

3. For RA330 specifically, use RA330-04 or RA330-80-15 weld fillers. Do not

use AWS E330 weld wire, as it will be crack sensitive. Do not try to weld RA330
with stainless rods such as E308, E309, or E310 as they are very likely to crack.
E312 electrodes are often sold under various tradenames for general shop repair
welding and dissimilar metal welds. Because of its very high Ferrite Number, E312
may make a sound weld in RA330. However, E312 weldments are not suited for
high temperature service. They embrittle severely with exposure above 600F
(1100C). At red heat E312 welds are very weak, as well as brittle. E312 should be
reserved for weldments to be used near room temperaturenever for austenitic
heat resistant alloy.

1
4. Make full penetration weld joints. Incompletely welded areas will open up
as cracks during normal heat treat thermal cycles. Incompletely penetrated weld
joints are the most common cause of weld failures in high temperature service.
Weld joints in fans, in particular, must be fully penetrated.

Let us back up a bit, and first describe some of the differences between welding carbon
steels, and welding either stainless or nickel alloys. Then, we will cover the important
differences between stainless (under 20% nickel) and the higher nickel alloys.

CARBON STEEL
This book is written assuming the reader understands how to weld ASTM A 36
structural steel (plain low carbon steel). Welding higher strength carbon steel requires a
somewhat different procedure, to ensure that the weld does not crack.
Welding is essentially a heat treating operation, as far as the steel is concerned. In
order to keep the weldment from cracking, it is important that it not form martensite on
cooling, i.e., that it not harden. This is not an issue with A 36 steel.
If the steel near the weld bead hardens, it is subject to hydrogen induced cracking,
within a few hours after the weld cools. This is also called underbead cracking,

because of its usual location. If there is no source for hydrogensuch as moisture in

the flux coating, shielding gas or surface contaminationthis cracking will not occur.
Even without hydrogen, a hard martensitic zone in the weldment may be unable to
withstand impact loading in service.
As the carbon content increases, along with manganese, and especially when
chromium and molybdenum are added, the potential for hardening during welding
increases. To prevent hardening, the steel may be pre-heated a few hundred degrees.
On cooling, this pre-heated steel now has time to transform to some phase other than
martensite by the time it reaches room temperature. This reduces hardness and
internal stresses. Steel in the range of 0.300.50% carbon usually requires some
preheat, along with low hydrogen welding practice.
Preheat and interpass temperatures in the 200400F range cover most medium
carbon steels. Alloy steels such as 4130 may require preheat in the 300450F range,
and 4140 350500F. ASTM A 387 Grade 11 preheat may range up to450F, with a
required post-weld heat treatment range of 11501350F, air cool. The higher
preheats are suggested for thicker sections.
This subject is covered well in the AWS Welding Handbook, Eighth Edition, Volume 4,
Part 2. Some pre- and post-heats are given in the ANSI/AWS D1.1 Structural Welding
Code. More detail, including required post-weld heat treatments, is in the Welding
Research Council bulletin 191, March 1978.
High sulphur free-machining steels, such as the AISI 11xx and 12xx series, may also be
subject to solidification cracking. This is usually a crack down the center of the weld
bead, or crater cracking. A higher manganese weld filler is suggested in such cases.

C.D. Lundin, P. Liu, C.Y.P. Qiao, G. Zhou, K.K. Khan, M. Prager, An Experimental
Study of Causes and Repair of Cracking of 1 Cr Mo Steel Equipment, Welding
Research Council, Bulletin 411, May 1996

CARBON STEEL VERSUS AUSTENITIC STAINLESS

Some important differences between welding the carbon or low alloy structural steels
and the austenitic stainless and nickel alloys include:
A. Surface Preparation
B. Shielding Gases C. Cold cracking vs Hot Cracking D. Distortion E. Penetration
F. Fabrication Time.
A. Surface Preparation
When fabricating carbon steels it is common practice to weld right over scale, red rust
and even paint. A so-called mill finish is a layer of blue-black oxide, or scale, on the
metal surface. Carbon steel weld fillers normally contain sufficient deoxidizing agents,

such as manganese and silicon, to reduce these surface iron oxides back to metallic
iron. The resultant Mn-Si slag floats to the weld surface. Iron oxide, or scale, melts at
a lower temperature, 2500F (1371C)1, than does the steel itself. One can see this in
a steel mill when a large ingot is removed from the soaking pit for forgingthe molten
scale literally drips off of the white hot steel.
Stainless steel, by contrast, must be clean and free of any black scale from hot rolling,
forging or annealing operations. Of course, stainless normally comes from the mill with
a white or bright finish. A few users of heat resistant alloys, though, do prefer black
plate, that is, plate with the mill hot rolling scale intact. This scale is thought to provide
additional environmental protection at red heat.
Stainless steel melts at a lower temperature than does its chromium oxide scale, and
the stainless weld filler chemistry is not capable of reducing this scale back to metallic
chromium. As a result, with gas shielded processes it is difficult to get the weld bead to
even wet, or stick to, a scaled piece of stainless. With SMAW a weld of sorts can be
made, as the coating fluxes away most of the scale.
The need to clean or grind down to bright metal is more likely to cause trouble when
stainless is being joined to carbon steel. That is because in this dissimilar metal joint it
is necessary to grind that carbon steel to bright metal, on both sides of the joint, free of
all rust, mill scale, grease and paint. Incidentally, the best weld fillers for this particular
joint, to minimize the hard martensitic layer on the steel side, are alloy 182 covered
electrode, ENiCrFe-3, or alloy 82 bare wire, ERNiCr-3. Alloy 62 bare wire, ERNiCrFe5, and ENiCrFe-2 covered electrodes are also appropriate. E309 electrodes are
commonly used but may leave a hard layer on the steel side, subject to cracking in
service.
Both those stainless and high nickel alloys which are designed for corrosion
resistance are produced to very low carbon contents, less than 0.03% and sometimes
less than 0.01% carbon. Any higher carbon will reduce the metals corrosion resistance
if welded. For this reason it is necessary to clean these alloys thoroughly of all traces of
grease and oil before welding. Also the very high nickel alloys, such as 400 alloy
(Monel, UNS N04400), or commercially pure nickel 200/201, are sensitive to weld
cracking from the sulphur in grease.
Metallic zinc paint is a common way to protect structural steel from corrosion. Even a
small amount of that zinc paint overspray on stainless or nickel alloy will cause the
metal to crack badly when welded. Consider completing all stainless welding before
painting the structural steel in the area.
Keep inorganic zinc paint away from any austenitic alloy!
B. Shielding Gases
For gas metal arc welding (a.k.a. MIG) carbon steel the shielding gases are usually
95% argon 5% oxygen, 75% argon 25% CO2 (carbon dioxide) or 100% CO2. These are

suitable with carbon or low alloy steel welding wire but far, far too oxidizing for use with
stainless or nickel alloys. It is not unknown to hear the complaint . . . clouds of red
smoke are coming off when I weld your 310. . . heavy spatter. . . and then learn that
the shielding gas used was 75%Ar 25%CO2.
A fine gas for carbon steel but
absolutely not for stainless.
One exception to this high CO2 prohibition is when using flux cored wire,
either stainless or nickel alloy. Some of these cored wires are specifically
formulated to run best with 75%Ar 25%CO2.
4
Stainless and nickel alloys have been GMAW spray-arc welded with 100% argon.
Weldability may be greatly improved by adding from 10 to 20% helium. 75% argon
25% helium is used, although it will not give a true spray-arc. At this lower level of
argon, arc transfer somewhat resembles globular transfer.
The weldability of stainless steel is impaired by the stable oxide film which exists on the
metal. A helium addition provides a little hotter arc, which helps to burn away that oxide.
A very small amount of CO2, about 1% or less, tends to stabilize the arc (prevents arc
wander). Two proprietary gases from Air Liquide, ArcalTM 121 and BlueShieldTM 20, are
designed specifically for stainless and nickel alloy GMAW.
The heat resisting alloy RA 602 CATM requires a nitrogen addition to the shielding gas
to avoid hot cracking. The recommended gas is CRONIGON HT, a patented gas
available from AGA and HOLOX in the USA, and from Linde Gas AG in Europe. This is
an argon-based gas with significant nitrogen, and small additions of active gases.
Strictly speaking, it is for MAG welding, Metal Active Gas, in European terminology.
CRONIGON HT may also be used for other highly alloyed heat resistant grades. It is
required for gas metal arc welding RA 602 CA.
Short-circuiting arc welding generally requires the 75%Ar 25%He mix, but a 90%He 7
1/2%Ar 2 1/2%CO2 tri-mix is commonly used. Carbon dioxide helps reduce arc
wander, by increasing emissivity of electrons from the work surface. The potential for
carbon pick-up from the CO2 is not an issue when welding heat resistant alloys. Shortcircuiting arc welding is used for sheet gages. With plate it may be necessary to grind
starts and stops to minimize lack of fusion defects.
C. Cold Cracking versus Hot Cracking
Carbon steel weldments may harden, and crack, as they cool from welding. High
hardness, and the resulting cracking, are more likely when the steel contains over
0.25% carbon. Alloying elements which increase hardenability, such as manganese,
chromium, molybdenum, etc., can make steels of lower carbon content also harden.
Hydrogen pickup from moisture in the air causes underbead cracking in steels that
harden as they cool from welding. To prevent such cracking the steel is usually
preheated before welding, to retard the cooling rate of the weld and avoid martensite

formation. Postweld heat treatment, or stress relief, is also applied to some steels, or
for certain applications.
Austenitic stainless and nickel alloys do NOT harden no matter how fast they cool from
welding. So, it is not necessary to preheat stainless, nor to post weld heat treat it. As a
matter of fact preheating stainless, beyond what may be necessary to dry it, can be
positively harmful. Stress relief 1100-1200F (600-650C) as applied to carbon steel is
only partially effective with stainless or nickel alloys, and may be damaging to the
aqueous corrosion resistance.
5
Stainless steel welds generally do not crack unless contaminated. This may be from a
surface smear of zinc or copper, less commonly by aluminum.
High nickel alloys are susceptible to cracking in restrained joints, or heavy sections.
This is a hot tearing (solidification cracking), not a cold crack. That is, the weld bead
tears rather than stretching, as the weld bead contracts upon solidifying. This hot
tearing/hot cracking has nothing to do with hardness. The faster a nickel alloy weld
freezes solid, the less time it spends in the temperature range where it can tear. For this
reason preheating, which slows down the cooling rate, is actually harmful, as it permits
more opportunity for hot tearing to occur.
D. Distortion2,3
Stainless steel has poor thermal conductivity, only about one fourth that of plain carbon
steel, such as A 36 structural steel. This means the welding heat tends to remain
concentrated, rather than spread out. Stainless also expands with heat about half
again as much as does carbon steel. The combination of these two factors means that
stainless or nickel alloy fabrications distort significantly more than similar designs in
carbon steel.
Among other things, tack welds need to be more closely spaced in stainless or nickel
alloy welds. Welds should be sequenced about the neutral axis of the fabrication to
balance welding stresses, hence minimize distortion. Back step welding is also helpful.
Tacks should be done in sequence, as well

6
If the tacks are simply done in order from one end, the plate edges close up

Weld runs should be done symmetrically about the joint's center of gravity to balance
stresses

12

10
8

5
4

2
1
3

6
9

7
11

Double V - joint

Flange to cylinder

7
Back step welding helps reduce distortion

E. Penetration
The arc will not penetrate a stainless nearly as deeply as it will carbon steel.
Penetration is even less in high nickel alloys. Increasing welding current will not solve
the problem! Stainless, and especially nickel alloy, joints must be more open, single or
double beveled, with a root gap, so that the weld metal may be placed in the joint. Lack
of weld penetration is the single most important reason why austenitic alloy weldments
fail in high temperature service.

F. Fabrication Time
Cleanliness, distortion control measures, maintaining low interpass temperatures and
even machining add up to more time spent fabricating stainless than carbon steel. A
shop experienced with stainless may require 1.6 times as long to complete the same
fabrication in stainless, as in carbon steel. A good carbon steel shop encountering
stainless or nickel alloys for the first time can easily spend twice as long, maybe even
three times as long, to do the stainless fabrication, as it would the same job in carbon
steel.
8

WELDING AUSTENITIC ALLOYS

The fundamental problem to be overcome in welding austenitic nickel bearing alloys is
the tendency of the weld to hot tear upon solidification. This matter is readily handled in
alloys under about 15% or so nickel. In these stainless grades the weld metal
composition is adjusted, usually by slightly higher chromium and reduced nickel, to form
a small amount of ferrite upon solidification.
The amount of ferrite in the weld may be measured magnetically, and is reported as a
Ferrite Number, FN. This ferrite acts to nullify the effects of the elements responsible for
hot cracking in the Ni-Cr-Fe austenitics. These elements are chiefly phosphorus,
sulphur, silicon and boron.
In higher nickel grades, over about 20% nickel, it is metallurgically impossible to form
any measurable amount of ferrite. Therefore other means of minimizing hot cracking
must be used. Foremost among these is to use high purity raw materials in the
manufacture of weld fillers. Phosphorus cannot be removed from stainless steel by
current refining methods. Whatever phosphorus comes from the raw materials, mostly
from the iron, will end up in the weld wire. Low silicon, when feasible, is desireable,
sulphur may be removed by the AOD refining process.
Phosphorus, in particular, must be kept below 0.015% in the weld wire itself.

Certain alloy additions such as manganese, columbium (niobium), molybdenum and

carbon serve in one way or another to reduce the austenitic propensity for weld hot
cracking. Manganese ranges from about 2% in AWS E310-15 covered electrodes to
5% in RA330-04 wire & electrodes and 8% in alloy 182 (ENiCrFe-3) covered electrodes.
A low level of columbium, such as the 0.5% in 347 stainless, is harmful, whereas 2 to
4% columbium is quite beneficial in many nickel base weld fillers.
Molybdenum isnt necessarily added specifically for weldability but it does enhance the
properties of RA333-70-16 covered electrodes. High molybedenum may be responsible
for the popularity of the various C type electrodes (15Cr 15Mo balance Ni) in repair
welding. 2% Mo contributes to 316 as being the most weldable of the stainless steels.
Carbon is slightly elevated in 310 weld fillers, to about 1/10%. The one welding
electrode specifically using high carbon to promote sound welds is the heat resistant
grade RA330-80-15 (UNS W88338). A weld deposit chemistry of some 0.85% carbon
permits this electrode to make sound welds in both wrought and cast 35% Ni high
silicon heat resistant alloys.
9
The distinction between the lower nickel stainless grades, which depend upon ferrite to
ensure weldability, and the high nickel alloys, which require high purity weld fillers, is an
important one to remember. Most ferrite containing (stainless) weld fillers are useless
with nickel alloy base metal, as dilution of the weld bead with nickel from the base metal
eliminates this ferrite. Likewise a high purity nickel alloy weld filler, such as ER320LR,
may be not quite so crack resistant when contaminated by phosphorus from use on
cast alloy 20 (CN-7M), 316L or carbon steel base metal.
With respect to welding there are some distinctions between those alloys intended for
use above 1000F (540C), and those meant for aqueous corrosion service. One
difference is in carbon content. Corrosion resistant grades are generally limited to
0.03% carbon maximum, and typically much lower. They may have small additions of
columbium or titanium. Restriction of carbon, or tying it up with a stabilizing element (Cb
or Ti) is necessary to prevent heat affected zone (HAZ) intergranular corrosion and
polythionic acid stress corrosion cracking (PASCC) due to carbide precipitation.
Heat resistant alloys by contrast typically require 0.04 - 0.010% carbon for good hot
strength. RA 602 CA is even higher, near 0.2%, while RA330HC belt pin stock and the
cast heat resistant alloys have a nominal 0.4% carbon. In the absence of a wet
corrosive environment a little intergranular carbide precipitation is not particularly
harmful.
In both classes of material, incompletely penetrated welds and open crevices must be
avoided in fabrication design. Serious aqueous corrosion can begin in crevices. In high
temperature carburizing service, crevices are where carbon (soot) can deposit, grow,
and pry the joint apart like tree roots in rock.

For either heat or corrosion resistant alloys, weldability alone is not the entire issue. The
weld filler must also have the mechanical and environmental resistance required for its
intended service. Usually this point is addressed in fabricating corrosion resistant alloys,
where a higher alloy weld filler is often used. It is sometimes overlooked in heat
resistant alloy fabrication. It is even less often considered in repair of high temperature
alloy fixturing.
ALLOYS UNDER 20% NICKEL

Most austenitic grades containing less than 20% nickel are joined with weld fillers that
utilize perhaps 4-12 FN (Ferrite Number) to ensure weldability. Wrought heat resistant
alloys with 20% or less nickel include 304H, 321, RA 253 MA, RA309, RA310. All save
RA310 depend upon some level of ferrite in the weld bead to prevent solidification
defects.
Ferrite does a good job of ensuring sound weldments. The covered electrodes used to
weld stainless steel are almost invariably AC/DC titania coated, designated either 16
or 17. Such electrodes have good welder appeal, and run exceptionally well when
direct current is used.

Schaeffler-de Long diagram from AvestaPolarits web site.

www.avestapolarit.com/template/page_2389.asp-16x

RA310 stands in an odd position between the stainless and the nickel alloys, having
neither ferrite nor any particular alloy addition for weldability. Not surprisingly, 310 welds
have a reputation for fissuring. The current AWS specification for ER310 weld wire
permits 0.030% phosphorus maximum. At this level of phosphorus austenitic weld
beads are very sensitive to hot cracking. For ER310 welding wire to be of practical use
the phosphorus must be kept under 0.015% maximum.
Because 310 is a difficult alloy to weld, the preferred choice in E310 covered electrodes
are the DC lime-type electrodes, usable only with direct current. The lime coating tends
to ameliorate the effects of impurities such as phosphorous. Even so, the phosphorus
level should be no higher than 0.015%. Titania coatings tend to be more crack
sensitive. It may be difficult to achieve sound welds in 310 base metal using an AWS
E310-16 AC/DC electrode.
In the past it was possible for 310S (UNS N031008) base metal to contain as much as
1.50% silicon in the ASTM/ASME specifications. Heats on the high side of silicon and
phosphorus were a problem to weld (Rolled Alloys had traditionally limited silicon in
RA310 to 0.75% max).
With the advent of 310H (UNS S31009), ASTM limited silicon to 0.75% maximum as
well. In practice all 310 varieties now melted in North America have less than 0.75% Si,
which is of some benefit to weldability.
ALLOYS OVER 20% NICKEL
Heat resistant alloys in this category include RA800H/AT, RA330 , RA 353 MA, 803,
alloy X (UNS N06002), RA333, 617, Haynes alloys HR-120, 230 and 214, 601, RA
602 CATM, 600, and Nimonic 75. The cobalt alloys N155, 556, 188, L605, and HR-160
may be treated in similar fashion with appropriate weld fillers.
Many nickel alloys are joined with matching composition weld fillers, modified only by
restrictions on phosphorus, sulphur, silicon and boron. Titanium may be added for
deoxidation. Other nickel weld fillers contain manganese, high carbon, columbium or
molybdenum to improve resistance to fissuring and hot cracking.
Such chemistry modifications are rarely as effective as is the use of ferrite in the lower
nickel stainless weld fillers. Welding technique and attention to cleanliness, then,
become increasingly important to ensure the soundness of fully austenitic welds.
Techniques include reinforced, convex stringer beads and low interpass temperature.

Cleanliness includes NOT using oxygen additions to the GMAW shielding gases for
nickel alloys.
11
It is worth repeating here that high nickel alloys cannot be reliably welded using
stainless steel weld fillers. Stainless steel (308, 309, etc.) depends upon a small
amount of deposited ferrite to ensure a sound weld. When a stainless rod is deposited
on a high nickel base metal, the resultant weld bead will include some nickel from the
base metal. It may be possible for that additional nickel to make the weld bead fully
austenitic, with no ferrite at all. Without ferrite, the stainless weld bead, already typically
a little high in phosphorus, may crack down the center.
While stainless steel welding electrodes are usually AC/DC titania, nickel alloy covered
electrodes are often produced with a lime-type DC coating. Shops accustomed to
stainless welding need to remember to switch to direct current, and to pay attention to
polarity. Normally one uses Reverse Polarity, that is, electrode positive, workpiece
negative.
RA333-70-16 is an exception among the high nickel electrodes, having an AC/DC
titania coating. For this reason it runs well, and tends to be readily accepted by welders.

S.J. Matthews, M.O. Maddock and W.F. Savage, How Copper Contamination Affects
Weldability of Cobalt Superalloys, Welding Journal, May 1972
R.J. Castro and J.J. deCadenet, Welding Metallurgy of Stainless and Heat-Resisting
Steels, Cambridge University Press, 1975
Berthold Lundqvist, Sandvik Welding Handbook, Sandvik AB, Sandviken Sweden 1977
E.F. Nippes and D.J. Ball, Copper Contamination Cracking: Cracking Mechanism and
Crack Inhibitors, Welding Research Supplement, Welding Journal, March 1982
T.G. Gooch Solidification Cracking of Austenitic Stainless Steel, pp31-40, Weldability
of Materials, ed. R.A. Patterson and K.W. Mahin, ISBN: 0-87170-401-3, ASM
International 1990

AGE HARDENING ALLOYS

The two age hardening (also called precipitation hardening) alloys to be covered here
are 17-4PH stainless, and the nickel alloy 718.
17-4PH metallurgy and welding
17-4PH is a low-carbon martensitic stainless steel. It is strengthened by a four hour
aging (precipitation hardening) treatment. 17-4PH is normally sold in the annealed
condition. Usually we think of annealed as meaning soft and ductile.

Annealed 17-4PH isnt especially hard, typically about Rockwell C30. But since
annealed 17-4PH is really untempered martensite, it has very low ductility and
notch impact strength.
Light gage 17-4PH may be welded in the annealed condition. This is followed by a postweld precipitation hardening treatment of 4 hours. Temperature should be in the range
of 950 to 1150F.
When making welds in heavy cross-sections, it is generally best to first age the metal to
condition H-1100 or H-1150. This makes the base metal more ductile, and less likely to
crack from welding stresses. The heat of welding will leave some zone of the base
metal in the annealed condition. Likewise, any matching 17-4PH filler metal will be in
the annealed condition. So after welding, the fabrication should again be aged for 4
hours, to regain strength and ductility in the weld area. For heavy sections, treatments
in the 950 to 1025F range are often used.
12
From the strict metallurgical viewpoint, it would be preferable to give the welded
fabrication a 1900F solution anneal. Then cool to room temperature, and age harden.
However that 1900F treatment becomes quite impractical with a large fabrication. In
practice, most 17-4PH fabrications are simply age hardened only, after welding.
For dissimilar welds involving 17-4PH stainless fillers such as 309 have been used.
The preferred fillers are alloy 82 (ENiCrMo-3) bare wire or the covered electrodes 182
(ERNiCrFe-3) and INCO-WELD A (ENiCrFe-2). These high nickel fillers have
thermal expansion coefficients more closely matching those of the 17-4PH. Their lower
strength and good ductility reduce the welding strains on the base metal, as the
weldment cools and contracts.
Heat treatments for 17-4PH and their designations
Designation

Processing

Condition A*

Heated at 1900F 25F for 12 hour, air cooled or oil

quenched to below 90F. This is the anneal, or solution
treatment, normally performed by the steel mill.

H 925, H 1025,
H 1075, H 1100

Condition A material which has been heated at the

specified temperature for 4 hours and air cooled.

H 1150-M

Condition A material heated at 1400 25F for 2 hours, air

cooled, then heated at 1150 15F for 4 hours and air
cooled. This heat treatment is used for maximum toughness,
and for cryogenic applications to 320F.

* For most applications, 17-4PH should not be used in Condition A. This is true even though the desired
tensile strength may be provided by that condition. While the alloy is relatively soft in Condition A, the
structure is untempered martensite that has low fracture toughness and ductility, with poor resistance to

stress-corrosion cracking. Superior service performance is assured by using 17-4PH in the age hardened
condtion.

Weld Fillers for 17-4PH

17-4PH is welded with fillers similar, but not identical, to the base metal.The
specifications for matching covered electrodes are AWS A5.4 E630, UNS W37410,
AMS 5827. Bare welding wire is in AWS A5.9 ER630, UNS S17480, AMS 5826

13
718 Metallurgy and Welding
718 is a fully austenitic nickel alloy. It is strengthened by a precipitation hardening
(a.k.a. age hardening) reaction involving columbium. A commonly used heat treatment
is to anneal 1700-1850F, rapid air cool or quench. This is the condition in which 718
normally is provided by the mill or by Rolled Alloys. Strength is achieved by aging at
1325F for 8 hours, furnace cool to 1150F, hold at 1150F for a total time of 18 hours
in the furnace, then air cool.
Cleanliness of both the base metal and the weld wire affect welding this grade. Freshly
cleaned 718 may be covered with plastic wrap to maintain cleanliness before welding.
E-Grade 718 weld wire GTAW wire with thoroughly mechanically cleaned surface is
available from stock for critical welding applications.
Heat input and interpass temperature should be low. Do not preheat. Make small
stringer beads, and remove all oxide film before depositing the next bead.
718 may be welded either in the annealed, or in the precipitation hardened condition.
For many non-aerospace applications the only heat treatment required after welding is
the 1325/1150F aging, to strengthen the weld bead and base metal near the fusion
line. This does leave a zone near the weld in an over-aged, relatively low strength,
condition. To maximize the properties of the weldment it is necessary to re-anneal
sheet gauges 1700-1850F, followed by 1325/1150F age.
For highly restrained joints where some reduction in weldment strength is permitted,
fillers such as 625 (ERNiCrMo-3) or Hastelloy W (ERNiMo-3) are sometimes used. 625
offers more strength than alloy W.
GTAW shielding is commonly argon torch and back-up gas, for material up to 1/4 thick.
Helium torch and back-up gas is preferred for heavier sections.
Weldments in 718 are subject to formation of a brittle Laves phase during solidification.
This reduces the strength and toughness of weldments. The effect is more pronounced
in plate gauges (over 3/16) than in sheet. Solution annealing 1900-1950F should redissolve the Laves phase and increase the tensile ductility of the weldment. Following

this higher temperature solution anneal the normal aging treatment is 1400F 10hours,
furnace cool to 1200F, hold at 1200F for a total aging time in the furnace of 18 hours,
air cool.
For highly restrained joints where some reduction in weldment strength is permitted,
fillers such as 625 (ERNiCrMo-3) or Hastelloy W (ERNiMo-3) are sometimes used. 625
offers more strength than alloy W.
14
GTAW shielding is commonly argon torch and back-up gas, for material up to 1/4 thick.
Helium torch and back-up gas is preferred for heavier sections.
Weldments in 718 are subject to formation of a brittle Laves phase during solidification.
This reduces the strength and toughness of weldments. The effect is more pronounced
in plate gauges (over 3/16) than in sheet. Solution annealing 1900-1950F should redissolve the Laves phase and increase the tensile ductility of the weldment. Following
this higher temperature solution anneal the normal aging treatment is 1400F 10hours,
furnace cool to 1200F, hold at 1200F for a total aging time in the furnace of 18 hours,
air cool.

F.G. Harkins, Welding of Age-Hardenable Stainless Steels, WRC Bulletin 103,

February 1965
M.Prager and C.S. Shira, Welding of Precipitation-Hardening Nickel Base Alloys, WRC
Bulletin 128, February 1968

MARTENSITIC

COPPER AND COPPER NICKEL

REACTIVE METALS
Titanium
Zirconium

Titanium Design Handbook for Industrial Applications, Section V: Design and

Fabrication, TIMET, 1999 Broadway, Suite 4300, Denver, Colorado 80202 USA
Zirconium Welding Brochure, Bulletin TWCA-8902W, Wah Chang, PO Box 460,
Albany, Oregon 97321 USA

DISSIMILAR METAL WELDING

Suggested Weld Filler Guidelines, Ni-Cr-Fe Austenitic Alloys
Considerations in selecting a filler metal for a dissimilar metal weld joint include the expected
service conditions at the joint, relative thermal expansion coefficients of the three metals
involved, and freedom from weld metal hot cracking. The final selection should be approved by
the end user and weld procedures qualified by the fabricator. These suggestions are from
experience and general metallurgical knowledge. 602 CA is a new alloy, data incomplete

Base
Metals

Carbon
Steel

Stainless
(304,316)

RA 253 MA

RA 602 CA Cast Alloys

HK, HT, HP

RA330
RA800H/AT

182
RA330-04

RA330-04

RA333

617A
RA330-04

182
RA333

RA330-04
RA333

RA333
RA330-04

617

RA333

RA330-80-15

RA333-70-16

RA 353 MA 182
RA 353 MA
RA 353 MA

RA 353 MA

-RA 353 MA
RA330-80-15

RA 253 MA E309-16

RA 253 MA
RA333
A
617

617A

RA333
RA333-70-16

82
182

RA333-70-16
RA330-80-15

TM

RA 253 MA

S 6025
6225 Al

RA333-70-16
RA330-80-15
A
617

RA 602 CA

182
82

182
82

RA600

82
182

82
182

RA601

82
182

82
182

RA333
RA333-70-16

S 6025
6225 Al

RA333-70-16
RA330-80-15

RA309

E309-16
182

E309-16
ER309

E309-16
RA 253 MA

82B
B
182

RA330-80-15

RA310

E309-16
182

E309-16
E310-15

RA 253 MA
--

82B
B
182

RA330-80-15
RA333-70-16

RA446

E309-16
E310-15

E309-16
E310-15

E309-16
RA 253 MA-17

82B
B
182

RA333-70-16
--

Note: The carbon steel joint must be ground to bright metal. A mill finish is not acceptable. All
rust, blue-black hot rolling scale and paint must be removed before welding with any stainless
or nickel alloy weld wires. Nickel alloy weld wire lacks the deoxidation characteristics of carbon
steel weld wires.
A
617 (ERNiCrCoMo-1) lacks the oxidation resistance of RA 602 CA
B
These high nickel fillers are quite unsuitable for sulphur bearing environments

Welding Dissimilar Metals, ed. N. Bailey, The Welding Institute, 1986

WELDING PROCESSES

Five different arc welding processes are generally used with heat resisting alloys. The
most common, in North America, is Gas Metal Arc Welding (GMAW), formerly known
as MIG (Metal Inert Gas), using spooled bare wire filler. Next in popularity is Shielded
Metal Arc Welding (SMAW), or just plain stick welding, with covered electrodes. The
least volume of work is done by Gas Tungsten Arc Welding (GTAW), formerly called

TIG (Tungsten Inert Gas) and originally trade named Heliarc . Two other methods are
Plasma Arc Welding (PAW) and Submerged Arc Welding (SAW). In addition
resistance welding, particularly cross wire resistance welding, is often used in heat
resistant alloy fabrication.

There are two basic types of welding machines, Constant Current, and Constant
Potential. A constant current machine is used for GTAW (TIG) and SMAW (stick)
welding. Practically speaking it wont work for GMAW (MIG) welding.
The dial on a Constant Current machine reads in amperes, and the current is regulated
by this dial. Constant Potential (voltage) machines are used for GMAW (MIG) welding.
They dont work well with covered electrodes (SMAW). The dial regulates voltage, and
is marked with numbers in the 20-40 range.

15
Gas Metal Arc Welding
In this process, the weld filler metal is bare wire. The most common size is 0.045 (1.14
mm), though 0.035 (0.89 mm) and 0.0625 (1.59 mm) are also stocked, typically on 2530 pound (11-14 kg) spools.
Wire is fed continuously through a hollow cable to the welding gun, where it makes
electrical contact. The arc between weld wire and workpiece melts the metal. Molten
weld filler transfers as either a spray of fine drops, or as larger globs. The metal is
protected from oxidation by a continuous flow of shielding gas, usually argon, through
the weld torch and around the wire. Current is always Electrode Positive (DCRP, direct
current reverse polarity).
The GMAW process is fast and well suited to high volume work. It can be automated,
as for welding long tubes. Welding with relatively high current, about 190-220 amperes
for 0.045 (1.14 mm) wire, and argon shielding is used for the spray-arc transfer mode.
In this mode, molten weld metal crosses the arc to the work as a fine spray. At lower
current, roughly 100 amperes for 0.035 (0.89 mm) wire, with 75% argon 25% helium
shielding, the molten weld metal transfers as large, individual drops. This is known as
short-arc, or short-circuiting arc, welding, characterized by a noisy arc, spatter, and low
heat input.
Choice of shielding gas is important. First, do not use oxygen additions to the gas when
welding nickel alloys and NEVER use 75% argon 25% carbon dioxide for
GMAW welding either stainless or nickel alloys. Oxygen above 2% starts burning out
major alloying elements. CO2 above 5% adds carbon to the low carbon stainless
grades. Although very small amounts of CO2 may be used in argon, at above 15% CO2

in argon the arc transfer mode is no longer spray, but rather a hot globular transfer with
a great deal of spatter.
For spray-arc welding the most common gas has been 100% argon. To improve bead
contour and reduce arc wander, respectively, from 10 to 20% helium and a small
amount of CO2 may be added to the argon. One such gas from Air Liquide, their
BlueShieldTM 20 is a nominal 81% argon 18% helium and 1% carbon dioxide. A mix of
75%Ar 25%He is also used, although the transfer mode will then not quite be a true
spray-arc. For short-circuiting arc transfer 75% Ar 25% He is used, as is the commonly
available 90% He 7 1/2% Ar 2 1/2% CO2.
Because the welding wire must be pushed through a cable, ranging from 10 to 15 feet
(3 to 4 1/2m) long, there may be feeding problems. The result can be a tangle of wire
known, appropriately, as a birds nest. This shuts down the operation until the welder
clears it. The care with which the filler metal is wound on the spool does affect how
smoothly the wire feeds. The manufacturer, then, is often blamed for feeding problems.
However, more often than not, proper attention to machine set up will ensure freedom
from birds nests.
16
Smooth feeding depends on the cast and helix of the spooled wire. Both AWS A5.9 for
stainless, and A5.14 for nickel alloy wire require cast and helix of wire on 12 inch
(300mm) spools to be4 such that a specimen long enough to produce a single loop,
when cut from the spool and laid unrestrained on a flat surface, will
do the following:
1. Form a circle not less than 15 in. (380mm) in diameter and not more than 50
in. (1300mm) in diameter
2. Rise above the flat surface no more than 1 in. (25mm) at any location Our
RA 253 MA wire, for example, typically has 36 to 42 inch (915 to 1070mm)
cast and 1/2 inch (12.7mm) helix.
The following discussion is based on information from Ron Stahura, Avesta Welding
Products, Inc.: Many heat and corrosion resistant alloy weld wires are much higher in
strength than stainless wire (e.g., ER308, ER316L), and therefore require more care to
feed smoothly. When tangling, or birds nest, occurs the first thing we suggest is to
examine machine set-up. Does this problem occur on more than one machine? How
long is the cablethe longer the cable, the more tension in the feed rolls. Are the feed
rolls, inlet guide and outlet guide all clean? Incidentally, V groove rolls are used with
solid stainless/nickel alloy wire, U groove for copper or aluminum, and serrated rolls for
flux cored wire.
Use minimal pressure on the feed rollsmore is not better. A rule of thumb is to hold
the wire between the fingers as it enters the feed rolls. If you can hold it back, there is
not enough pressure. Adjust the pressure until you just can not hold the wire, then give
it another half turn beyond that.

For 0.045 inch (1.14mm) wire, consider using a 1/16 inch (1.6mm) conduit, instead of a
0.045/1.14mm conduit. The oversize conduit wont hurt, and will give more room for
the wire to flex.
A heavy duty contact tip is preferred instead of a standard contact tip. When spray-arc
welding the tip runs hot, and the wire may swell into the tip and jam it. The heavy duty
tip simply has more copper, and can handle more heat.
17

Gas Metal Arc Welding GMAW, a.k.a. MIG)

Flux Cored Arc Welding
FCAW is similar to GMAW except that the wire used is tubular, with flux and metal alloy
powders inside. Because this wire contains its own flux, gas shielding may be 75%
Argon 25% CO2, even with nickel alloys!
The advantage of flux cored wire is greater overall productivity than when solid wire is
used, and the arc is softer. Flux cored wire is sensitive to moisture pick-up, and
should be left in its sealed plastic bag until ready to use.

Flux Cored Arc Welding (FCAW)

18
Shielded Metal Arc Welding
Covered welding electrodes consist of an alloy core wire and a flux coating. The
core wire is usually, but not always, similar to the base metal in composition. Often,
however, various alloy additions are made in the coating, so that the weld bead
chemistry will not be the same as the chemistry of the core wire itself.
In the case of RA330-80-15 or -16, and most RA330-04-15 covered electrodes, a
35%Ni 15%Cr AWS E330 core wire is used. The additional carbon, manganese and
chromium required in the weld deposit are added to the flux coating. During welding,
these additions melt in and adjust the chemistry of the weld bead to the specified
composition. RA333-70-16 electrodes do use RA333 core wire. The electrode coating
does four basic jobs:
1.

Provides a gas that shields the metal crossing the arc from oxidation

2.

Produces a molten slag which further protects the molten weld bead from
oxidation, affects out-of-position weldability, and controls the bead shape

3.

Adds more alloying elements, such as manganese, carbon or chromium

4.

Promotes electrical conductivity across the arc and helps to stabilize the
arc, important when alternating current (AC) is used

There are three types of coatings used on Rolled Alloys electrodes. Coating type is
designated by a -15, a -16, or, more recently, a -17.

DC lime-type coatings are designated -15. RA330-04-15 and RA330-80-15 both have
DC (Direct Current) lime coatings. This means that these electrodes can ONLY be used
with direct current. Normally the current is reverse polarity (DCRP, or Electrode
Positive). That is, the electrode is the positive, and the workpiece is negative electrical
pole of the circuit. Electrons are emitted from the work and go toward the electrode.
If the welder attempts to use a DC electrode with an AC (alternating current) setting on
the welding machine, the electrode simply wont run. He will not be able to keep the arc
going. This would seem to be very basic knowledge, but every couple of years
someone complains that RA330-04-15 wont run. Well, it will indeed run on DC
current, but not on AC. That is, not unless that AC current is turned up so high that the
whole electrode glows red and the coating spalls off.
The AC/DC titania coated electrodes are designated -16. RA333-70-16 and RA330-8016 both have AC/DC coatings. These electrodes may be used with
19
alternating current (AC). They have compounds of potassium and titanium in the
coating which stabilize the arc. This means it will not extinguish itself as the current
reverses direction (and goes to zero) 60 times a second on normal 60 cycle current (50
cycle in Europe).
AC/DC electrodes may also be used with direct current, DC. In fact, they run the best
when using DC.
Weld repair with RA333-70-16 covered electrodes is best
accomplished using direct current, reverse polarity (DCRP).
The newer coating designation is -17, which also operates on alternating current, as
well as on direct current. At this writing RA 253 MA-17 is the only electrode we stock
with this coating.
Remove all slag or flux after welding!
If there is any residual weld flux on the fabrication, that flux will continue to do its job
when put into high temperature service. The result will be one form or another of hot
corrosion, dependent upon the atmosphere. Fluoride containing fluxes are wonderful
getters for sulphur. Residual flux may lead to local sulphidation attack even though the
sulphur level is quite low in the surrounding atmosphere. This has been well illustrated
in work published by the former Huntington Alloy Products Division, now Special Metals.
In carburizing environments, Rolled Alloys experience has been that the flux will
promote rapid carburization, hence embrittlement. In carbon and sulphur free oxidizing
environments that flux will increase local oxidation rates.

Gas Tungsten Arc Welding

In GTAW, the arc is struck between the workpiece and a tungsten electrode, which
remains unmelted. The argon shielding gas, which protects both the hot tungsten
electrode and the molten weld puddle, is brought in through a nozzle or gas cup which
surrounds the electrode. This process used to be called TIG (Tungsten Inert Gas), and
was originally patented as Heliarc , a name still used occasionally.
For both stainless and nickel alloys the current used is DCSP, direct current straight
polarity. The work is electrically positive and the tungsten electrode is the negative
electrical pole. The electrode is usually thoriated tungsten, that is, tungsten metal with 1
or 2% thorium oxide added to improve the emissivity of electrons. Rare earth oxides are
also used. For welding aluminum the electrode is pure tungsten, used with AC
(alternating current).
20
Shielding gas is normally pure argon or helium. Argon is used for manual welding. A
helium addition may be used for automated welding, where a hotter arc is preferred. No
oxygen or carbon dioxide can be tolerated or the tungsten electrode would literally burn
up. For the new heat resistant nickel alloy
RA 602 CA, it is necessary to add
2.5% nitrogen to the argon. In this particular alloy, nitrogen reduces hot cracking
susceptibility.
The arc between the tungsten electrode and the work is what melts the workpiece. The
weld filler metal is fed by hand into the molten puddle. GTAW weld wire for heat or
corrosion resistant alloys is sold as 36 (914 mm) straight lengths of bare wire, in 10
pound (4 1/2 kg) tubes.
The welder has the most control when using gas tungsten arc, and this process makes
the best quality weld, but it is relatively slow. It may be automated for volume
production. In automatic GTAW the wire is fed into the joint from a spool of wire, just
like GMAW wire. For faster welding speed helium is added to the argon shielding gas,
making the arc hotter. GTAW is often used to make the root pass in pipes or whenever
the joint can only be made from one side. The rest of the weld may be built up with
either GMAW or SMAW, both of which are faster.
Rememberthe core wire of RA330-04-15 covered electrodes is AWS ER330, and not
RA330-04 chemistry. Welders sometimes knock the coating off an electrode and use
the core wire as GTAW filler. Do not do this with RA330-04-15 or the RA330-80
electrodes. This AWS ER330 will make a crack-sensitive weld, without the benefit of
the alloying elements which were in the coating.
Atmospheric contamination, as from strong winds or too long an arc length, is a
potential cause of porosity. Look at work to tip distance, shielding gas flow rates,
cup size and consider the use of a gas lens. When using a 24% nitrogen addition for
welding RA 602CA or some of the corrosion resistant alloys, the shielding gas will be
just that much more sensitive to atmospheric contamination.
Minimize the arc length, no more than 1/4 to 3/8 inch (6-9.5mm). The longer the arc
length, the greater the opportunity to entrain air into the shielding gas. Gas cup size

depends upon what diameter tungsten electrode is being used. A 3/32 (2.4mm)
electrode should use anywhere from a No. 6 to No. 8 cup (9.5-12.7mm cup dia), No. 7
(11mm) being about right. An 1/8 inch (3.2mm) electrode requires a No. 8 (12.7mm)
cup. Consider using a gas lens, a wire screen which serves to reduce turbulence of the
shielding gas flow. It is this turbulence which causes air to get mixed in with the argon
shielding gas.

21

Gas Tungsten Arc Welding (GTAW, a.k.a. TIG)

Plasma Arc Welding

The plasma arc torch is roughly analogous to a GTAW torch. It generates intense heat
in a very narrow zone, and has been used to weld RA330 without added filler (with
GTAW this would be extremely difficult). PAW is an excellent welding process for heat
resisting alloys.

For the corrosion resistant alloy AL-6XN , plasma welding is less desirable. This 6% molybdenum grade
requires the use of an over-alloyed weld filler, typically ERNiCrMo-3, to maintain corrosion resistance in
the weld bead. With plasma arc welding so little filler is used that the weld bead is heavily diluted with
base metal and has reduced corrosion resistance due to molybdenum micro segregation. A full 2150F
(1177C) anneal is necessary to restore full corrosion resistance in plasma welds of AL-6XN.

Submerged Arc Welding

Submerged arc uses a spool of weld wire, much like GMAW. Instead of shielding gas,
a hopper feeds granulated flux into the arc to shield the arc and molten weld puddle.

While it is possible to use 0.045 (1.14 mm) dia. wire, larger sizes such as 1/16 or 3/32
(1.6 or 2.4 mm) are generally preferred. For nickel alloys such as RA330 a strongly
basic flux must be used, such as Avesta Flux 805 or Bhler-Thyssens RECORD
NiCrW. Absolutely do not use acid fluxes or any flux meant for stainless steel. Heat
input must be as low as possible, and for this reason 1/8 (3.2 mm) wire is not
suggested with nickel heat resistant alloys.

22

SAW is process naturally inclined to high heat input, but this heat must be kept to a
minimum to avoid centerbead cracking in fully austenitic alloys. It is for this reason that
3/32 (2.4mm), rather than 1/8 (3.2mm), wire is suggested for use with nickel heat
resistant alloys.

Resistance Welding3

23

Spot and seam welding parameters for heat resistant alloys will differ from those used
with stainlesses such as 304L or 316L, and markedly from those used for carbon steel.
Heat resistance alloys may have twice the yield strength of stainless and considerably
higher electrical resistivity. Electrode force, welding current and time, and electrode tip
contours may all need to be modified accordingly.
A restricted-dome electrode is suggested for spot welding. Average dome radius may
be 3 inch (76 mm) for material up to 11 gage (3mm). For a larger nugget size in
material 16 to 11 gage (1.6 to 3mm) a 5 to 8 inch (127 to 203mm) radius dome is
sometimes preferred.

In seam welding heat time should be adjusted to ensure that the wheel maintains
pressure until the weld nugget has solidified, to avoid porosity and cracking. Likewise
cool time should be sufficient that welded areas are not remelted. The
metal must be clean and free of all grease, or a sound weld cannot be made.

24
Suggested Weld Filler Selections
Base Metal

Preferred
bare wire
covered electrodes

Alternates

RA330

RA330-04
--

RA330-04-15
RA330-80-15

RA333 , RA82
RA333-70-16

RA333

RA333

RA333-70-16

ERNiCrWMo-1

RA 602 CATM

S 6025
6225 Al
(SG-, EL- NiCr25FeAlY)

RA601

S 6025
RA333

6225 Al

RA600

82

182

RA 353 MA

RA 353 MA

RA 353 MA

RA 253 MA

RA 253 MA

RA 253 MA-17

RA333, RA333-70-16

RA800H/AT

RA333
556

RA333-70-16
--

ERNiCrCoMo-1
RA330-04
82, ENiCrFe-2

RA309

ER309

E309-16

RA 253 MA-17

RA310

ER310

E310-15

RA330-04*

RA446

ER309
ER310

E309-16
E310-15

E312-16

HK, HT, HU

RA330-80-15 DC lime is the preferred 35% nickel rod for cast

heat resistant alloys. Alternates RA333-70-16, RA330-04-15

617
(2.4627,
ERNiCrCoMo-1)
--

RA330-04
--

General: Do choose the weld filler for its performance under the expected service conditions, as
well as for weldability issues.
*Where sulphidation is an issue, do not use high nickel fillers such as RA330-04
Do not useany stainless weld filler on nickel alloys (e.g., on RA330, RA333, RA600, RA601,
RA 353 MA, RA 602 CA). The welds will crack. We suggest not using alloy X (ERNiCrMo-2,
ENiCrMo-2) weld fillers on RA333 base metal. The X weld bead may be subject to catastrophic
oxidation at the higher service temperatures where RA333 is commonly used. Alloy 617
(ERNiCrCoMo-1) welds are strong, but they significantly lack oxidation resistance compared
with RA 602 CA for extreme temperature service.

25
Dissimilar Metal Joints, Suggested Weld Filler Guidelines
Considerations in selecting a filler metal for a dissimilar metal weld joint include the expected
service conditions at the joint, relative thermal expansion coefficients of the three metals
involved, and freedom from weld metal hot cracking. The final selection should be approved by
the end user and weld procedures qualified by the fabricator. These suggestions are from
experience and general metallurgical knowledge. 602 CA is a new alloy, data incomplete

Base
Metals

Carbon
Steel

Stainless
(304,316)

RA 253 MA

RA 602 CA Cast Alloys

HK, HT, HP

RA330
RA800H/AT

182
RA330-04

RA330-04

RA333

617
RA333

RA330-80-15

RA333

182
RA333

RA330-04
RA333

RA333
RA330-04

617A

RA333-70-16

RA 353 MA 182
RA 353 MA
RA 353 MA

RA 353 MA

617A
6225Al

RA 353 MA
RA330-80-15

RA 602 CATM 182

82

182
82

617A

S 6025
6225 Al

617A

RA 253 MA E309-16

RA 253 MA
E309-16

RA 253 MA
RA333

617A

RA333-70-16
RA330-80-15

RA600

82
182

82
182

RA333
RA333-70-16

82
182

RA333-70-16
RA330-80-15

RA601

82
182

82
182

RA333
RA333-70-16

S 6025
6225 Al

RA333-70-16
RA330-80-15

RA309

E309-16
182

E309-16
ER309

E309-16
RA 253 MA

82
182B

RA310

E309-16
182

E309-16
E310-15

RA 253 MA
--

RA446

E309-16
E310-15

E309-16
E310-15

E309-16
RA 253 MA-17

RA330-80-15

82
182B

RA330-80-15
RA333-70-16

82B
182B

RA333-70-16
--

Note: The carbon steel joint must be ground to bright metal. A mill finish is not acceptable. All
rust, blue-black hot rolling scale and paint must be removed before welding with any stainless
or nickel alloy weld wires. Nickel alloy weld wire lacks the deoxidation characteristics of carbon
steel weld wires.
A
617 (ERNiCrCoMo-1) lacks the oxidation resistance of RA 602 CA
B
These high nickel fillers are quite unsuitable for sulphur bearing environments

26
Dissimilar Metal Weldments Involving Carbon Steel

27

Heat Resistant Alloy Weld Filler Metals

Grade

UNS

RA330-04
N08334
RA330-04-15 W88334
RA330-80-15 W88338
RA330-80-16 W88338
RA333
N06333
RA333-70-16 W86333
RA 253 MA S30815
RA 253 MA-17 W30816
RA 353 MA - RA 353 MA-15 - 309-16
W30910
310-15
W31010
S 6025
N06025
6225 Al
-230-W
N06231
617
N06617
82
N06082
182
W86182

AWS

Cr

Ni

Mo

Co

Si

Mn

Fe

Other

----------E309-16
E310-15
ERNiCrFe-12
ENiCrFe-12
ERNiCrWMo-1
ERNiCrCoMo-1
ERNiCr-3
ENiCrFe-3

19
17.5
17.5
17.5
25
25
21
21
28
28
23
26
25
25
22
22
19
16

35
33.5
33.5
33.5
45
45
10
11
34
35
13
20
63
62
59
52
72
65

----3
3
--------2
9
---

----3
3
---------12.5
---

----3
3
--------14
----

0.8
0.8
0.8
0.8
1
1
1.6
1.7
0.7
0.5
0.5
0.4
0.03
0.5
0.5
0.5
0.2
0.6

5.2
5.2
2.2
1.7
3
2.5
0.6
0.7
1.7
1.5
1.9
1.8
0.05
0.1
0.6
0.5
3
7.8

0.25
0.22
0.85
0.85
0.05
0.05
0.07
0.06
0.03
0.08
0.10
0.10
0.18
0.2
0.1
0.1
0.02
0.04

39
43
45
45
17
18
66
65
35
34
61
51
9
10
1.5
1.5
2
7.5

------0.16 N 0.05 Ce
0.17 N 0.04 Ce
N, Ce
0.15 N 0.03 Ce
--2.2 Al 0.08 Y
2.3Al 0.1Ti
0.3 Al
1.2 Al 0.4 Ti
2.7 Cb 0.5 Ti
2Cb

23

Heat Resistant Alloy Specifications

alloy

UNS

RA333

N06333 Plate, sheet, strip

Bar
Smlss pipe & tube
Welded pipe
Welded tube
N08330 Plate, sheet, strip
Bars & shapes
Billets & bars
Smlss pipe & tube
Welded pipe
Welded tube
Fusion weld pipe
N06025 Plate, sheet
Rod, bar,wire
S30815 Plate, sheet, strip
Bars and shapes
Pipe
Welded tube

RA330

RA 602 CATM
RA 253 MA

RA 353 MA

RA800H/AT

S35315

N08811
(N08810)

RA309

S30908

RA310

S31008

RA446
RA600

S44600
N06600

RA601

N06601

Product Form

ASME

Plate, sheet, strip

Bars and shapes
Pipe
Plate, sheet, strip
Rod and bar
Smlss pipe & tube
Plate, sheet, strip
Bars and shapes
Pipe
Plate, sheet, strip
Bars and shapes
Pipe
Plate, sheet, strip
Plate, sheet, strip
Rod, bar, wire
Smlss pipe & tube
Plate,sheet, strip
Rod, bar, wire
Bar, forgings,rings
Smlss pipe & tube
24

ASTM AMS W.Nr, EN

-B 718 5593 2.4608

-B 719 5717
-B 722
-B 723
-B 726
SB-536 B 536 5592 1.4886
SB-511 B 511 5716
-B 512
SB-535 B 535
SB-710 B 710
-B 739
-B 546
-B 168 - 2.4633
-B 166
SA-240 A 240 - 1.4893
SA-479 A 479
1.4835
SA-312 A 312
SA-249 A 249
ASME Code Case 2033-1
SA-240 A 240 - 1.4854
SA-479 A 479
SA-312 A 312
SB-409 B 409 - -SB-408 B 408 - (1.4876)
SB-407 B 407
SA-240 A 240 - 1.4833
SA-479 A 479
1.4833
SA-312 A 312
SA-240 A 240 5521 1.4845
SA-479 A 479 5651 1.4845
SA-312 A 312
-A 176 - 1.4763
SB-168 B 168 - 2.4816
SB-166 B 166 5665
SB-167 B 167
SB-168 B 168 5870 2.4851
SB-166 B 166
--5715
SB-167 B 167

Weld Filler Specifications & Tradenames, American versus German

Grade

UNS No.

AWS

W. Nr.

DIN Designation

RA330-04
RA330-04-15
RA333
Alloy X
601
S 6025
6225 Al
617
62
82
182
80-20

N08334
W88334
N06333
N06002
N06601
--N06617
N06062
N06082
W86182
N06076

---ERNiCrMo-2
ERNiCrFe-11
--ERNiCrCoMo-1
ERNiCrFe-5
ERNiCr-3
ENiCrFe-3
ERNiCr-6

--2.4608
2.4613
-2.4649
-2.4627
-2.4806
2.4620
2.4951

--NiCr26MoW
SG-NiCr21Fe18Mo
-SG-NiCr25FeAlY
EL-NiCr25FeAlY
SG-NiCr22Co12Mo
-SG-NiCr20Nb
EL-NiCr16FeMn
NiCr 20Ti

25

Boltsanother means of joining heat resistant alloys

Bolts are commonly used at elevated temperature to withstand a shear load. For example,
RA330 alloy threaded rod, nuts and washers are used to assemble high temperature
equipment where loose joints are desired to accommodate thermal expansion & contraction
during thermal cycling.
A good discussion of fasteners in the chemical process industry has been presented by Robert
Smallwood6.
At high temperatures relaxation is the primary limitation to the use of threaded fasteners to
maintain a clamping load. The most common alloy choice for applications up to 1150 or 1200F
(620-640C) is RA718, an age hardening nickel base alloy. A286, a less expensive age
hardening stainless, is sometimes suggested but it does not have as high a temperature
capability as does RA718, and is not nearly so available in various bar sizes. Above this
temperature, to about 1400-1500F (760-816C) the choices narrow down to Ren 41 or
WASPALOYTM. More of this high temperature bolting experience has been with WASPALOY.
In addition to selecting a strong bolt material it is important to look at the relative expansion
coefficients of the alloy to be clamped, and the alloy from which the bolt is made. If the metal to
be clamped expands faster than the bolt, that expansion will add to the tensile load in the bolt
and may stretch it, so that the assembly is loose once it comes back down to room temperature.
What appear to us as fairly liberal alloy selection suggestions are offered by the Industrial
Fasteners Institute as7: Below 450F (230C), low alloy steel. 450 to 900F (230 to 480C), one
of the grades in ASTM A 193. From 900 to 1200F (480 to 650C), A286 and 718 . Above
1200F up to 1600F (650 to 870C), Rene 41 or WASPALOY.
Some cautions. Never, NEVER use anti-seize compounds containing copper anywhere near
high temperature equipment. If some of that copper gets carried into an area where the metal is
operating above 1981F (1083C) it will melt. Molten copper alloys will embrittle or eat holes
through any austenitic alloy they touch. Zinc or galvanized coatings embrittle austenitics and
can also embrittle steel bolts at moderately elevated temperatures, even without melting the
zinc (melting point 787F/419C).
Bolted connections are often difficult or impossible to disassemble after high temperature
exposure. One of the reasons is that a chromium oxide scale forms on the alloy. This oxide
tends to bond male and female threads together. There are ways to minimize the strength of
this bond. One is to coat both parts with magnesium hydroxide, commonly available from the
local drug store as Phillips Milk of Magnesia. This will calcine to magnesium oxide, quite inert
and harmless to heat resistant alloys. The magnesia simply acts as a parting compound.
Another approach is to use a braze stop-off, such as one of those available from Wall
Colmonoy Corporation, www.colmonoy.com.

26

Weld Filler Consumption

Filler metal requirements range from about 2-1/2 to 5 percent of the weight of plate
involved in a fabrication. Estimated weight of covered electrodes and spooled wire for
various joint configurations is given below.

APPROXIMATE WEIGHT, IN POUNDS, OF

PLATE
THICKNESS,
inch

WELD METAL
DEPOSITED PER
LINEAL FOOT
WITH
REINFORCEMENT

COVERED
ELECTRODES
REQUIRED (A)

GMAW,
GTAW
WIRE
REQUIRED
(B)

SINGLE FILLET

1/8
3/16
1/4
3/8
1/2
5/8

0.032
0.072
0.13
0.29
0.52
0.80

0.064
0.144
0.26
0.58
1.03
1.61

0.038
0.085
0.15
0.34
0.60
0.94

"V" GROOVE

1/4
3/8
1/2

0.37
0.62
0.85

0.73
1.23
1.7

0.43
0.73
1.00

DOUBLE "V"
GROOVE

1/2
5/8
3/4
1

0.77
0.95
1.32
1.83

1.53
1.90
2.63
3.65

0.90
1.12
1.55
2.16

JOINT DESIGN

(A) Assumes 50% deposition efficiency

(B) Assumes 85% deposition efficiency

27
References
1. Thaddeus B. Massalski, Editor-in-Chief, Binary Alloy Phase Diagrams, Volume 1,
ISBN 0-87170-262 American Society for Metals, Metals Park, Ohio, U.S.A., 1986

2. Avesta handbook for the welding of stainless steel, Inf. 8901, Avesta Welding AB, S-74401
Avesta, Sweden 1989
3. Berthold Lundqvist, SANDVIK Welding Handbook, Sandvik publication 0,34 E, Sandvik AB,
Sandviken, Sweden June, 1977
4. Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods, ANSI/AWS
A5.14/A5.14M-97, ISBN 0-87171-543-0, American Welding Society, Miami, Florida, U.S.A.
5. Resistance Welding Manual, 4th Edition, ISBN 0-9624382-0-0, Resistance Welder
Manufacturers Association, 1900 Arch Street, Philadelphia, Pennsylvania 19103 USA, 1989
6. R.E. Smallwood, Fastener Problems in the Process Industry, Corrosion 91
Paper No. 161, NACE, Houston, Texas
7. Fastener Standards, 6th Edition, available from: Industrial Fasteners Institute,
1505 East Ohio Building, 1717 East Ninth Street, Cleveland, Ohio 44114 U.S.A.
The best general reference we know for welding this class of materials is: R. J. Castro & J.J. de
Cadenet, Welding Metallurgy of Stainless and Heat-resisting Steels, ISBN 0 521 20431 3,
Cambridge University Press, 1975. First published, in French, as: Mtallurgie du soudage des
aciers inoxydables et rsistant chaud, by Dunod, Paris, 1968.

28

Weld Filler Specifications & Tradenames, American versus German

Grade
Nr.

---

UNS No. AWS Classification

DIN Designation
F No.
N08334
--W88334 --N06333
--2.4608
NiCr26MoW
W86333 --N06002
A5.14 ERNiCrMo-2
2.4613
SG-NiCr21Fe18Mo
ERNiCrFe-11
--ERNiCrFe-12
-2.4649

-SG-

--

ENiCrFe-12

--

EL-

A5.14

ERNiCrCoMo-1

2.4627

SG-

A5.11

ERNiCrFe-5
ERNiCr-3
ENiCrFe-3

-2.4806
2.4620

-SG-NiCr20Nb
EL-

2.4951

NiCr 20Ti

RA330-04
RA330-04-15
RA333
RA333-70-16
Alloy X
601
N06601
S 6025
-NiCr25FeAlY
6225 Al
-NiCr25FeAlY
617
N06617
NiCr22Co12Mo
62
N06062
82
N06082
182
W86182
NiCr16FeMn
80-20
N06076

ERNiCr-6

--

43
43

ASME

W.

----

---

---

-??

--

--