Aug 17, 2015

7 Key Factors to Consider When Selecting a Filler Metal

Using a filler metal that provides the appropriate mechanical and chemical properties for the job — and is able
to withstand the service conditions the weld encounters — is critical. It helps minimize the risk of cracking,
corrosion and/or weld defects that could lead to time-consuming and costly rework.
There are seven key factors to consider when selecting a filler metal: the base material to be welded, the
welding position, regulatory specifications and codes, design requirements, shielding gas, post-weld heat
treatment and welding equipment. Below is a detailed look at each of these factors and how they dictate which
filler metal to use.
Factor No. 1: The base
material to be welded
Joining together two
materials is, for the most
part, a matter of chemistry:
Which filler metal best
matches the base material?
If the chemistry of the
materials matches, the
mechanical properties (such
as the tensile and yield
strength) will also match.
Welding operators can rest
assured that their weld
deposit will have the same
strength and properties as
the base material.
When materials being joined
are not the same strength,
there are other
considerations. As a rule of
thumb, welding operators
should match the strength of
the filler metal to the lower
strength of the two base
materials. During the welding
process, dilution from the
higher strength base material
is sufficient to strengthen the
weld metal deposit.
Most base metals can easily
be identified through tests
based on appearance and
reactions to magnets,
fracture, chisel, and flames
or sparks and a welding
Using a filler metal that provides the appropriate mechanical operator typically knows
what base material he or she
and chemical properties for the job — and is able to withstand is working with. In some
the service conditions the weld encounters — is critical. cases — usually during
repair or rework welding — it
may be necessary to take a
sample to a lab that can conduct a chemical analysis.
Factor No. 2: The welding position
Whenever possible, welding operators should rotate the part so it can be welded in a flat position. Welding in a
flat position is always the most economical, followed by horizontal or vertical and, lastly, an overhead position.
If a welding operator must work with a large weldment that can’t be manipulated, however, it forces the need to
weld in multiple welding positions. Out-of-position welding can be especially challenging if there is only one
wire size available. For example, a vertical weld up using a 3/32-inch-diameter wire may be extremely difficult
or even impossible. A better choice would be a wire ranging from .045 to 1/16 inches in diameter, but it would
require setting up an additional wire feeder or another power source for the job. It would also require a change
in feed rolls and, potentially, the welding gun. Companies should keep in mind that changing welding positions
can slow the process and compromise efficiency, and when possible select a filler metal type and size that will
allow for the most versatility.
Factor No. 3: Regulatory specifications and codes
Job specifications often dictate what class of wire to use. If not, welding operators should carefully consider the
service requirements the welds may encounter.
For example, if a welding operator uses a mild steel filler metal for applications exposed to harsh elements, it is
likely that the welds will rust, deteriorate and corrode at a faster rate than the base material. This action could
lead to weld failures, especially if the end product is of critical importance, such as a pressure vessel used in
high-temperature environments or a bridge that will be exposed to the elements.
In the end, whatever filler metal a welding operator uses must also meet the service condition of the final
product so that the weld deposit lasts as long as the base material. It’s equally important when welding to code
that the filler metal should meet the qualifications or certification of that code.
Factor No. 4: Design requirements
In addition to following codes (when required), it is important to select a filler metal that meets or exceeds the
needs of a joint design, as specified by the engineer’s welding configuration. For instance, when welding on
thin material, it is important that the arc characteristics are appropriate — a wire that provides deep penetration
may cause the welding operator to burn through. On the other hand, if the part to be welded is thick and
features a single “V” joint, a filler metal with better penetration characteristics allows for better tie-in at the root
and sides.
Factor No. 5: Shielding gas
It’s important to ensure the filler metal and shielding gas used for an application are compatible. Different
shielding gases have different effects on filler metal. For example, the addition of argon to CO2 allows the
welding operator to transfer more of the filler metal’s chemistry into the weld deposit. This mixture provides
consistent weld quality, offers good weld pool control and generates lower levels of spatter. However, by
transferring a richer chemistry from the filler metal into the weld deposit, it also increases the risk of potential
cracking.
Conversely, using CO2 (an oxidizing
gas) burns off some of the filler metal
elements. 100 percent CO2offers the
advantage of deep weld penetration,
which is desirable when welding thicker
materials. It tends, however, to have
larger ball transfer and can create more
spatter than shielding gas mixtures that
are a combination of Argon and CO2.
There are wires capable of operating
with both straight CO2 and an
argon/CO2 mixture. Companies should
consider their available gas supply and
desired weld characteristics provided
by each when choosing a filler metal,
and make sure that the selected filler
metal is compatible with the shielding
gas chosen.
Factor No. 6: Post-weld heat
treatment
There are certain steels and material
thicknesses that must be preheated to
a certain temperature before welding Job specifications often dictate what class of wire to use.
commences. Preheating allows the part
to cool down at a slow rate to avoid
If not, welding operators should carefully consider the
weld-shrinking issues and cracking. service requirements the welds may encounter.
Similarly, post-weld heat treatment
(PWHT) is used to reduce the stresses and slowly lower the residual heat introduced during welding, allowing
the weld joint and base materials to return to the desired properties. On materials that require PWHT, it is
important to select a filler metal capable of producing welds that respond appropriately to the application of
heat.
Factor No. 7: Welding equipment
The type and size of equipment being used impacts what filler metal is best for the job. Specifically, the power
source needs to provide enough amperage for the diameter of wire being used for the job. In the event that
there is not enough amperage, it will be necessary to change wire diameters, which could result in slower
production to complete the weld, or change to a higher-capacity machine. It’s also important for the power
source to offer the proper welding current for the filler metal chosen. Welding in the wrong current can lead to
spatter and poor weld quality.
Determining the desired weld characteristics is equally important. Filler metals that operate on reverse polarity
(electrode positive, or EP) provide great penetration, while straight polarity (electrode negative, or EN) filler
metals produce a more shallow joint penetration.
Conclusion
Although the effect of various elements in filler metals can be rather complex and inter-related, a review of their
general properties can also help welding operators determine which filler metal is ideal for the job.
Carbon, for example, generally increases hardness, tensile strength and wear resistance, but decreases
ductility, impact and machinability. Nickel, on the other hand, increases hardness, tensile strength, impact and
ductility, but decreases the part’s ability to be machined. Similarly, there are various alloying elements that
have different properties to deoxidize, refine grain structures or improve ductility. It is important for welding
operators to consider the properties needed in a completed weld when making the filler metal selection.
For additional information about welding metallurgy and how to select the best filler metal, consult your local
welding equipment distributor or a trusted filler metal manufacturer.