Welding — filler selection
Pick a welding filler / electrode
The lookup table every WPS engineer keeps in a binder. Type a base metal, see the recommended filler classification, AWS spec, and process notes — same metals AND dissimilar pairs.
55 of 55 pairs
A36 / A516 (CS) ⇄ A36 / A516 (CS)
preheat: ≥10 °C ambient · 80 °C if t > 25 mm
PWHT: optional below t=38mm
recommended filler
| E7018 | AWS A5.1 | SMAW | low-H workhorse |
| ER70S-2 + E7018 | A5.18 + A5.1 | GTAW root + SMAW fill | highest quality root |
| E71T-1 | A5.20 | FCAW | productive flux-core |
| EH14 / Lincolnweld 880 | A5.17 | SAW | shop fab |
A106 (CS pipe) ⇄ A106 (CS pipe)
preheat: 10 °C ambient (≥80 °C if t>19 mm)
PWHT: optional
recommended filler
| E7018 | AWS A5.1 | SMAW | B31.3 default piping electrode |
| ER70S-2 + E7018 | A5.18 + A5.1 | GTAW root + SMAW fill | oil-and-gas spec |
P11 (1.25Cr-0.5Mo) ⇄ P11 (1.25Cr-0.5Mo)
preheat: 150 °C
PWHT: mandatory 690 ± 14 °C / 1 h per inch
recommended filler
| E8018-B2 | AWS A5.5 | SMAW | matching B2 chemistry |
| ER80S-B2 | AWS A5.28 | GTAW | tube-mill / repair |
P22 (2.25Cr-1Mo) ⇄ P22 (2.25Cr-1Mo)
preheat: 200 °C
PWHT: mandatory 720 ± 14 °C
recommended filler
| E9018-B3 | AWS A5.5 | SMAW | matching B3 |
| ER90S-B3 | AWS A5.28 | GTAW | tube-mill |
| F9P0-EB3-B3 | A5.23 | SAW | header fab |
P91 (9Cr-1Mo-V-Nb) ⇄ P91 (9Cr-1Mo-V-Nb)
preheat: 200-250 °C · interpass <300
PWHT: mandatory 760 ± 10 °C / 4 h min · STRICT
recommended filler
| E9015-B91 / E9018-B91 | AWS A5.5 | SMAW | matching B91; PWHT critical to develop tempered martensite |
| ER90S-B91 | AWS A5.28 | GTAW | most common root pass |
⚠ Warning: P91 PWHT is not optional — under-PWHT yields a brittle as-welded martensite that fails creep test. Hold within ±10 °C and document.
304L (UNS S30403) ⇄ 304L (UNS S30403)
preheat: none (austenitic — pre-heat causes sensitization)
PWHT: NOT permitted (carbide precipitation)
recommended filler
| E308L-16 | AWS A5.4 | SMAW | 0.04 % max C, low-C matching filler |
| ER308L | AWS A5.9 | GTAW | highest quality |
| ER308LSi | AWS A5.9 | GMAW | Si for fluidity |
316L (UNS S31603) ⇄ 316L (UNS S31603)
preheat: none
PWHT: NOT permitted
recommended filler
| E316L-16 | AWS A5.4 | SMAW | sour-service spec |
| ER316L | AWS A5.9 | GTAW | most common piping |
| ER316LSi | AWS A5.9 | GMAW | thicker shop fab |
2205 duplex (S31803) ⇄ 2205 duplex (S31803)
preheat: none
PWHT: not required; if applied: 1050-1100 °C solution-anneal
recommended filler
| E2209-16 | AWS A5.4 | SMAW | ~22 Cr 9 Ni 3 Mo overmatch Ni for ferrite control |
| ER2209 | AWS A5.9 | GTAW | N₂ in shielding gas (1-2 %) recommended |
| E2209T1-1 | A5.22 | FCAW | productive duplex flux-core |
⚠ Warning: 2205 needs heat-input control: 0.5-2.5 kJ/mm to keep austenite/ferrite balance. Avoid PWHT — reanneal if exceeded.
2507 super-duplex (S32750) ⇄ 2507 super-duplex (S32750)
preheat: none
PWHT: not required
recommended filler
| ER2594 | AWS A5.9 | GTAW | 25Cr-9Ni-4Mo overmatch + 2.4 % Mn |
| E2594-16 | AWS A5.4 | SMAW | sour-service piping |
⚠ Warning: Heat input 0.5-1.5 kJ/mm strict. N₂ shielding mandatory for GTAW.
316L (austenitic) ⇄ A106 (carbon steel)
DISSIMILARpreheat: 50 °C · CS-side rules govern
PWHT: NOT permitted (austenitic side)
recommended filler
| ER309L / E309L-16 | AWS A5.9 / A5.4 | GTAW + SMAW | higher Cr/Ni overmatch dilutes CS pickup, prevents martensite at fusion line |
alternatives
| E309LMo | AWS A5.4 | SMAW | when service requires Mo (CS side at ~150-300 °C) |
| ENiCrFe-3 (Inconel 182) | AWS A5.11 | GTAW | when CTE-mismatch fatigue is a concern |
⚠ Warning: NEVER use 308L for SS-to-CS — CS dilution drops Cr below 18, martensite forms, joint fails on first thermal cycle.
316L (austenitic) ⇄ P22 (Cr-Mo)
DISSIMILARpreheat: 150 °C · P22-side rules govern
PWHT: compromise — partial PWHT below sensitization (450 °C max)
recommended filler
| ENiCrFe-3 (Inconel 182) / ERNiCr-3 (Inconel 82) | A5.11 / A5.14 | GTAW + SMAW | Ni-base buffer — matches CTE between austenitic + ferritic better than 309L |
alternatives
| ER309L / E309L-16 | A5.9 / A5.4 | GTAW + SMAW | cheaper but CTE mismatch causes thermal-cycle fatigue at high T |
2205 duplex ⇄ A106 (carbon steel)
DISSIMILARpreheat: 50 °C
PWHT: not permitted (duplex side anneal-only)
recommended filler
| E2209-16 / ER2209 | A5.4 / A5.9 | GTAW + SMAW | standard 22-9-3 filler dilutes ~20 % from CS without losing duplex balance |
alternatives
| ERNiCrMo-3 (Inconel 625) | A5.14 | GTAW | when fatigue-sensitive or service > 300 °C |
Inconel 625 (N06625) ⇄ Inconel 625 (N06625)
preheat: none
PWHT: not required (precipitation-hardening alloys excepted)
recommended filler
| ERNiCrMo-3 | AWS A5.14 | GTAW | matching 625 chemistry |
| ENiCrMo-3 | AWS A5.11 | SMAW | thicker shop fab |
Inconel 625 (N06625) ⇄ 316L stainless
DISSIMILARpreheat: none
PWHT: NOT permitted
recommended filler
| ERNiCrMo-3 / ENiCrMo-3 | A5.14 / A5.11 | GTAW + SMAW | Ni-base side dominates |
Hastelloy C-276 ⇄ Hastelloy C-276
preheat: none
PWHT: not required
recommended filler
| ERNiCrMo-4 | AWS A5.14 | GTAW | matching C-276 |
| ENiCrMo-4 | AWS A5.11 | SMAW | shop fab |
5083 Al-Mg ⇄ 5083 Al-Mg
preheat: none (Al — risk of HAZ over-aging)
PWHT: not applicable
recommended filler
| ER5183 | AWS A5.10 | GTAW (AC) | matching Mg, AC for cleaning |
| ER5356 | AWS A5.10 | GMAW (pulse) | most-used for marine 5xxx |
CP Ti Gr 2 (R50400) ⇄ CP Ti Gr 2 (R50400)
preheat: none
PWHT: not required
recommended filler
| ERTi-2 | AWS A5.16 | GTAW (Ar shield only) | matching CP-Ti; full Ar trailing shield mandatory |
⚠ Warning: Ti welding: any O₂/N₂ contamination (>500 ppm) = embrittlement. Trailing shield + back-purge mandatory. No air gap allowed.
A572 Gr 50 (HSLA) ⇄ A572 Gr 50 (HSLA)
preheat: 40 °C above 19 mm · 80 °C above 25 mm
PWHT: often optional
recommended filler
| E7018-1 | AWS A5.1 | SMAW | low-H workhorse for HSLA |
| E71T-1C | AWS A5.20 | FCAW | productive for structural |
A516 Gr 70 (CS plate) ⇄ A516 Gr 70 (CS plate)
preheat: 10 °C above 12 mm · 80 °C if t>38 mm
PWHT: mandatory above 38 mm
recommended filler
| E7018-A1 if PWHT | AWS A5.5 | SMAW | A1 has 0.5Mo for PWHT toughness |
| ER70S-2 + E7018 | A5.18 + A5.1 | GTAW root + SMAW fill | pressure-vessel standard |
| F7A0-EM12K-H4 | A5.17 | SAW | shop fab |
API 5L X65 (line pipe) ⇄ API 5L X65 (line pipe)
preheat: 10-50 °C
PWHT: not typical for transmission
recommended filler
| E8018-G + ER70S-G | AWS A5.5 + A5.18 | GTAW root + SMAW fill | mainline X65 girth weld |
| E7018 | AWS A5.1 | SMAW | standard X42-X52 |
API 5L X70 (line pipe) ⇄ API 5L X70 (line pipe)
preheat: 50 °C
PWHT: not required
recommended filler
| ER80S-G + E8018-G | AWS A5.18 + A5.5 | GTAW root + SMAW | matching strength + low-H |
A350 LF2 (low-T forging) ⇄ A350 LF2 (low-T forging)
preheat: 50 °C · interpass <250
PWHT: mandatory for −46 °C MDMT
recommended filler
| ER70S-2 + E7018-A1 | A5.18 + A5.5 | GTAW root + SMAW fill | low-T impact-tested |
⚠ Warning: For LNG / cryogenic service, qualify Charpy at design min temp · NORSOK M-630
A333 Gr 6 (low-T pipe) ⇄ A333 Gr 6 (low-T pipe)
preheat: 10-100 °C
PWHT: optional unless governed by code
recommended filler
| E8018-C3 (1Ni) | AWS A5.5 | GTAW + SMAW | 1 % Ni filler for −46 °C qual |
9% Ni cryogenic ⇄ 9% Ni cryogenic
preheat: none (avoid HAZ overaging)
PWHT: not required
recommended filler
| ERNiCrMo-3 (Inconel 625) | AWS A5.14 | GTAW | Ni-base over-matches strength + cryogenic toughness |
| ENiCrMo-6 | AWS A5.11 | SMAW | LNG ship hulls, qualified to −196 °C |
⚠ Warning: NEVER use matching 9 % Ni filler - inadequate toughness in HAZ. Use Ni-base.
P5 (5Cr-½Mo) ⇄ P5 (5Cr-½Mo)
preheat: 200-260 °C
PWHT: mandatory 730 ± 14 °C
recommended filler
| E502-15 / E502-16 | AWS A5.4 | SMAW | matching 5Cr filler |
| ER502 | AWS A5.9 | GTAW | tube fab |
P9 (9Cr-1Mo) ⇄ P9 (9Cr-1Mo)
preheat: 200-260 °C
PWHT: mandatory 730-760 °C
recommended filler
| E505-15 | AWS A5.4 | SMAW | matching 9Cr (legacy pre-P91) |
| ER505 | AWS A5.9 | GTAW | tube |
P92 / NF616 ⇄ P92 / NF616
preheat: 200-300 °C · interpass <300
PWHT: mandatory 770 ± 10 °C / 4 h min
recommended filler
| E9015-G | AWS A5.5 | SMAW | matching B92 chemistry |
| ER90S-G (B92 type) | AWS A5.28 | GTAW | supercritical boiler |
⚠ Warning: P92 PWHT critical — under-cure same risk as P91
321 (Ti-stab) / 347 (Nb-stab) ⇄ 321 / 347
DISSIMILARpreheat: none
PWHT: NOT permitted
recommended filler
| ER347 (Nb-stab) / ER321 (Ti is rare for filler) | AWS A5.9 | GTAW | high-T service — Nb stabilizer preferred |
| E347-16 | AWS A5.4 | SMAW | refining hot service |
317L / 317LMN ⇄ 317L / 317LMN
preheat: none
PWHT: NOT permitted
recommended filler
| ER317L | AWS A5.9 | GTAW | higher Mo for severe pitting |
| E317L-16 | AWS A5.4 | SMAW | pulp + paper bleach |
904L / N08904 ⇄ 904L / N08904
preheat: none
PWHT: NOT permitted
recommended filler
| ER385 (904L) | AWS A5.9 | GTAW | matching 904L super-austenitic |
| E385-16 | AWS A5.4 | SMAW | sulfuric acid service |
254 SMO (S31254) ⇄ 254 SMO (S31254)
preheat: none
PWHT: NOT permitted
recommended filler
| ERNiCrMo-3 (alloy 625) | AWS A5.14 | GTAW | over-match Ni-base prevents Mo segregation in weld |
| ENiCrMo-3 | AWS A5.11 | SMAW | sea water |
⚠ Warning: Matching 254-SMO filler segregates Mo. Use Ni-CrMo over-match.
410 / 13Cr martensitic ⇄ 410 / 13Cr martensitic
preheat: 200-260 °C
PWHT: mandatory 700-730 °C if hardness > 22 HRC
recommended filler
| E410-16 | AWS A5.4 | SMAW | matching martensitic |
| E309L-16 | AWS A5.4 | SMAW (austenitic for ductility) | tougher weld but mismatched composition |
17-4 PH (S17400) ⇄ 17-4 PH (S17400)
preheat: 50 °C
PWHT: solution + age (per Condition H1025/H1075)
recommended filler
| ER630 (matching 17-4) | AWS A5.9 | GTAW | matching PH chemistry |
⚠ Warning: PWHT temperature governs final aged strength · solution-anneal then age
Lean duplex 2304 ⇄ Lean duplex 2304
preheat: none
PWHT: not typical · solution anneal if needed
recommended filler
| ER2307 / ER2209 | AWS A5.9 | GTAW | over-match Ni for ferrite balance |
| E2307-16 / E2209-16 | AWS A5.4 | SMAW | austenite-balance critical |
ZERON 100 (S32760) ⇄ ZERON 100 (S32760)
preheat: none
PWHT: not required
recommended filler
| ER2594 / Z100X | AWS A5.9 | GTAW | matching W + Cu super-duplex |
Inconel 600 (N06600) ⇄ Inconel 600 (N06600)
preheat: none
PWHT: not required
recommended filler
| ERNiCrFe-5 / ERNiCr-3 | AWS A5.14 | GTAW | matching 600 for furnace muffles |
Inconel 690 (nuclear) ⇄ Inconel 690 (nuclear)
preheat: none
PWHT: not required
recommended filler
| ERNiCrFe-7 (Alloy 152) | AWS A5.14 | GTAW | Alloy 52/152 nuclear SG tubes — replaces 600 for SCC resistance |
Hastelloy B-3 (N10675) ⇄ Hastelloy B-3 (N10675)
preheat: none
PWHT: not required
recommended filler
| ERNiMo-7 | AWS A5.14 | GTAW | matching B-3 for HCl service |
Alloy 22 (N06022) ⇄ Alloy 22 (N06022)
preheat: none
PWHT: not required
recommended filler
| ERNiCrMo-10 | AWS A5.14 | GTAW | matching Alloy 22 |
| ENiCrMo-10 | AWS A5.11 | SMAW | severe oxidising chloride |
Alloy 59 (N06059) ⇄ Alloy 59 (N06059)
preheat: none
PWHT: not required
recommended filler
| ERNiCrMo-13 | AWS A5.14 | GTAW | matching Alloy 59 ultra-corrosion |
Monel 400 (N04400) ⇄ Monel 400 (N04400)
preheat: none
PWHT: not required
recommended filler
| ERNiCu-7 (Alloy 60) | AWS A5.14 | GTAW | matching Monel chemistry |
| ENiCu-7 | AWS A5.11 | SMAW | HF acid + sea water |
Inconel 800 / 800H ⇄ Inconel 800 / 800H
preheat: none
PWHT: not required
recommended filler
| ERNiCr-3 / ERNiCrFe-2 | AWS A5.14 | GTAW | high-T furnace alloy |
P22 (Cr-Mo) ⇄ A106 (CS)
DISSIMILARpreheat: 200 °C (P22-side dominates)
PWHT: mandatory if P22 thickness > 12 mm
recommended filler
| E8018-B2 (P22 chemistry) | AWS A5.5 | SMAW | PWHT temperature compatible w/ both sides |
| ER80S-B2 | AWS A5.28 | GTAW | matched to P22 |
P91 (9Cr) ⇄ A335 P22 (2¼Cr)
DISSIMILARpreheat: 200-250 °C · interpass <300
PWHT: mandatory at 740-760 °C (P91 limit)
recommended filler
| E9015-B91 (matching P91) | AWS A5.5 | SMAW | P91 chemistry dominates because of creep |
⚠ Warning: Type IV cracking risk at HAZ — verify Charpy at PWHT temp
P91 (9Cr) ⇄ A106 (CS)
DISSIMILARpreheat: 200 °C
PWHT: compromise — often skip on CS-only side
recommended filler
| ENiCrFe-3 (Inconel 182) | AWS A5.11 | GTAW + SMAW | Ni-base buffer better than direct welding for repeated thermal cycling |
Inconel 600/625 ⇄ A106 (CS)
DISSIMILARpreheat: 50-150 °C (CS-side)
PWHT: NOT permitted (Inconel-side)
recommended filler
| ENiCrFe-3 / ERNiCr-3 | A5.11 / A5.14 | GTAW + SMAW | standard Inconel-CS dissimilar — buffer layer + filler |
6061 Al-Mg-Si ⇄ 6061 Al-Mg-Si
preheat: minimal · risk of overaging
PWHT: not applicable
recommended filler
| ER4043 (Al-Si) | AWS A5.10 | GTAW (AC) | Si-bearing prevents hot cracking |
| ER5356 (Al-Mg) | AWS A5.10 | GMAW | higher strength than 4043 |
7075 Al-Zn-Mg-Cu ⇄ 7075 Al-Zn-Mg-Cu
preheat: NOT recommended (HAZ degradation)
PWHT: solution + age required to recover strength
recommended filler
| ER5356 (best of bad options) | AWS A5.10 | GTAW (AC) | 7075 is essentially unweldable for structural use; FSW preferred |
⚠ Warning: 7xxx series aluminum is largely unweldable for primary structure · use FSW or mechanical fastening
Ti-6Al-4V (R56400) ⇄ Ti-6Al-4V (R56400)
preheat: none
PWHT: optional anneal at 540-705 °C
recommended filler
| ERTi-5 / ERTi-9 | AWS A5.16 | GTAW (Ar) | matching 6-4 with O₂ control |
⚠ Warning: Same Ti rules: trailing shield + back-purge + clean cavity mandatory
CP Ti Gr 7 (Pd-bearing) ⇄ CP Ti Gr 7 (Pd-bearing)
preheat: none
PWHT: not required
recommended filler
| ERTi-7 (matching Pd) | AWS A5.16 | GTAW | preserve Pd for crevice resistance |
Gray cast iron ⇄ Gray cast iron
preheat: 300-540 °C · slow cool
PWHT: slow cool only · stress-relieve at 540 °C
recommended filler
| ENiFe-CI (55%Ni / 45%Fe) | AWS A5.15 | SMAW (Ni-base) | standard cast-iron repair · machinable |
| ENi-CI | AWS A5.15 | SMAW (pure Ni) | when crack-free is critical, machinable |
| ESt (steel) | AWS A5.15 | SMAW (graphitic) | cheap but not machinable |
⚠ Warning: Cast-iron welding risks cracking from rapid cooling. Slow cool below 200 °C in dry insulation.
H13 hot-work tool steel ⇄ H13 hot-work tool steel
preheat: 370-480 °C · maintain through weld
PWHT: temper after weld
recommended filler
| ER80-B2 / matching H13 | AWS A5.5 / A5.28 | GTAW | die repair |
⚠ Warning: Tool-steel repair welding requires temperature control at every step
90/10 CuNi (C70600) ⇄ 90/10 CuNi (C70600)
preheat: none
PWHT: not required
recommended filler
| ERCuNi (alloy 67) | AWS A5.7 | GTAW | matching 90/10 seawater HEX |
70/30 CuNi (C71500) ⇄ 70/30 CuNi (C71500)
preheat: none
PWHT: not required
recommended filler
| ERCuNi-3 (alloy 67) | AWS A5.7 | GTAW | matching 70/30 seawater |
Aluminum bronze (C95400) ⇄ Aluminum bronze (C95400)
preheat: minimal
PWHT: not typical
recommended filler
| ERCuAl-A2 | AWS A5.7 | GTAW | pump impeller repair |
Sources: AWS A5.1 (low-alloy steel SMAW) · A5.4 (SS SMAW) · A5.5 (low-alloy SMAW) · A5.9 (SS bare) · A5.10 (Al) · A5.11 (Ni-base SMAW) · A5.14 (Ni-base bare) · A5.16 (Ti) · A5.17 (CS SAW) · A5.18 (CS bare) · A5.20 (CS FCAW) · A5.22 (SS FCAW) · A5.23 (low-alloy SAW) · A5.28 (low-alloy bare). Always confirm vs the procedure-qualification record (PQR) for the intended service.