How to select welding electrodes and filler wires?

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How to select welding electrodes & filler wires?


Electrodes and filler wires are selected based on the matching metallurgy with that of base meterial/ parent material. 

When the word 'metallurgy' comes it makes a feel that this is going to be a complicated topic. 

There will be many ready to use material available in internet in this topic. But is there any authenticity in those documents? 

Here we are discussing about some codes/standards that gives a ready reference on this topic. The data in these documents can be used directly in the mentioned applications (Procedure qualification and WPS are to be established). Anyway the best is to get approved by desig engineer, welding engineer, client or consultant.

1. API RP 582: Welding Guide lines for the Chemical,  Oil and GAS industries.


API RP 582 is one of the documents which gives an easy selection of welding consumables.

Table A. 1 gives the selection of welding consumables for Carbon and Low alloy steel. 
Table A. 2 gives welding consumables for stainless steels. 
Table A. 3 Duplex stainless steels. 
Table A. 4 Copper Nickel and Nickel alloy steels. 
This document can be referred for temperatures of PWHT, preheat and interpass temperature. 
This document can be referred for dissimilar welding. 

2. AWS D1.1 Structural Steel Welding Code

This code gives a direct selection of welding consumables in  table 4.9 to the  corresponding base metals listed in the table. This table lists SMAW, SAW, GMAW  and FCAW process. 
The selection and usage of other process and Welding Consumable can also be done complying the code guidelines. 

3. ASME BPVC Section IX, Standard WPS

The standard welding procedure specifications (SWPSS) can be used after purchasing it. SWPSS is not a welding consumable selection guide but SWPSS will give an idea of most commonly used consumable for the combination of base material P Nos.

4. Other Codes and Standards 

The above are some of the codes which gives a ready reference. The other familiar codes like ASME 31.3, API 570, API 650 etc. does not gives a selection process.

Normally the welding consumable to be used will be in the project specification. There are rare cases where we have to select the consumables. In such cases even if we select, the approval has to be given by the design engineer / client / welding engineer

4. Catalog of welding consumable manufacturers.


Catalog of welding consumable manufacturers are another good source for the selection.
Below are the links to the catalog of some of the consumable manufacturers. 


b) ESAB 





Go through each catalog,  the electrodes and the corresponding materials that can be welded will be in the catalog. Please note that if any special properties are needed on the electrodes (such as impact testing requirements or a restricted ferrite number or any other special conditions) that is to be mentioned while ordering those consumables.

Welding consumables are also available in different packing. Example: SMAW electrodes are available in normal packing and in Vacuum Packing.
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