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Re: [MW:35682] Welding Expertise Required for Dissimilar Materials

By Materials & Welding

Dear Sir,

We appreciate your detailed query regarding the welding of dissimilar materials—IS 2062 E250 Gr.BR (a carbon structural steel) to AISI 420 (a martensitic stainless steel). Please find our recommendations below:

1. Suitable Electrodes for Dissimilar Welding

a) SMAW Process (Shielded Metal Arc Welding):

For joining IS 2062 to AISI 420, austenitic stainless steel electrodes are generally preferred to accommodate the differences in mechanical and metallurgical properties. We recommend:

  • E309L-16 or E309-16
    These electrodes offer good compatibility with both carbon steel and martensitic stainless steel, while providing austenitic weld metal that helps reduce cracking.

b) GMAW Process (Gas Metal Arc Welding):

For GMAW (MIG welding), suitable filler wires would be:

  • ER309L or ER309
    These wires provide excellent fusion and mechanical properties for dissimilar welding between carbon steel and stainless steel.

Note: Preheat may be required (especially for AISI 420) to reduce hardness and cracking tendencies. Post-weld heat treatment (PWHT) may also be considered depending on the service condition.

2. Equivalent Specification for AISI 420 as per ASME Standards:

  • The nearest ASME equivalent for AISI 420 is typically UNS S42000, which corresponds to:

    • SA-240 Type 420 (for plate),

    • or SA-182 Type 420 (for forged bars and flanges),

    • or SA-479 Type 420 (for bars and shapes).

Best regards,

Nilesh Boricha - Boricha Group / FabX  Technocrats / SunRay Weldcrats
đź“ž +91 84016 62421
✉️ nilesh.boricha@borichagroup.com



On Fri, Jun 13, 2025 at 5:40 PM pankaj pachahara <pankajpachahara@gmail.com> wrote:
Dear Expert's

I hope this email finds you well. I am working on a project involving welding of dissimilar materials. The materials are IS 2062 E250 Gr.BR and AISI 420.

Could you please provide guidance on the following:

1. Suitable electrodes for welding IS 2062 E250 BR to AISI 420 using:
- Shielded Metal Arc Welding (SMAW) process
- Gas Metal Arc Welding (GMAW) process
2. Equivalent material specification for AISI 420 as per ASME standards

Your expertise would be greatly appreciated in helping us determine the most suitable welding approach and materials for this project.

Thank you for your time and assistance.

Best regards,
Pankaj Choudhary

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