TECHNICAL AWARENESS BULLETIN

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GUIDES FOR DISSIMILAR METAL WELDING (DMW)

Scope
Dissimilar metal welding (DMW) has generated a
number of technical papers and large detailed filler
metal selection tables. Many DMW's in the Process
Industry do not involve demanding service
requirements where special filler metal selection
would be in order. This Bulletin is a guide for
commonly encountered DMW's and cites areas of
caution where special welding considerations might
be needed.
Metallurgical Considerations
In a DMW the properties of three metals must be
considered; the two base metals being joined and
the filler metal/base metal composite resulting from
joining them. Figure 1 is a simple illustration of a
weld between two different metals and a 15% base
metal dilution from each metal while the filler metal
contributes 70% to the total weld nugget
composition. This illustrates the point that dilution
from the base metals can make a significant
contribution to the weld nugget composition and
subsequently to the weld properties. The actual
amount of base metal dilution will vary (higher or
lower) depending on the welding process, welding
parameters, and the base metal.
Another important consideration in DMW's is the
heat affected zone (HAZ) in both metals being
joined. The rule is to use the same welding
parameters in making the DMW that would be used
in welding one of the metals to itself. An example
would be where one metal is a low alloy steel and
preheat and/or post weld heat treatment is required
in welding to itself, the same practice should be
followed in making a DMW. On occasion there may
be a conflict in that the optimum control for one
metal is undesirable for the other in which case a
compromise is needed.
Weld Corrosion/Oxidation Residence
The weld should have corrosion/oxidation resistance
equal to the least resistant base metal being joined.
It is fortunate that in most all instances the weld will
be of a higher alloy content (better corrosion and
oxidation resistance) than the least resistant base
metal being joined. When a DMW is in an

environment where the liquid can be an electrolyte,

the weld metal should be cathodic to (more
corrosion resistant than) both base metals. If the
weld is anodic (less corrosion resistant), it can suffer
accelerated galvanic corrosion due to area effects.
The Owner must, however, consider the specific
application as corrosion effects might have little
significance in some applications while strength
differences may be of far greater importance.
Welding Processes:
A welding process and procedure capable of
producing welds of low dilution is beneficial. This is
consistently obtainable with SMAW (stick welding),
GMAW (MIG short circuiting or pulsed arc) and
FCAW (flux core) welding processes. With GTAW
(TIG) welding the amount of filler metal is controlled
by the welder and they may need instruction to
make the proper and consistent amount of fillermetal addition for the particular welding procedure.

Frequently Asked Questions

1) When does the difference in coefficient of
thermal expansion (CTE) become a factor? A
common example would be welds between carbon
steel and 304 (L) stainless steel with an austenitic
stainless steel filler metal that has a 30% higher
CTE than ordinary steel. The difference is not
considered a problem up to 800F (425C) and
above this temperature a Ni-Cr-Fe filler metal
provides a better CTE match. With other material
combinations with a significant CTE difference and
high temperature cycling, calculations may be
advisable.
2) What metals can not be fusion welded to
iron, nickel or copper base alloys? Aluminum,
titanium, zirconium and tantalum to name the more
common metals can not be fusion welded to iron,
nickel and copper base alloys. They may be joined
by processes such as explosion bonding, bolting or
brazing.

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with implementing any recommendations.
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GUIDES FOR DISSIMILAR METAL WELDING (DMW)

3) Is a welding procedure required for each
DMW procedure? If a code such as ASME is
involved, a procedure qualification is required even
though qualification tests have been made for two
like metals welded to each other. The tensile
strength (TS) of a DMW should be the minimum TS
of the weaker of the two base metals or the weld
metal or if the break occurs outside the weld, not
more than 5% below the minimum TS of the base
metal. For non-code work, a procedure qualification
is always advisable.
4) In making a transverse bend test for a welding
qualification test, why does a fracture
consistently occur in the HAZ of one of the base
metals? This may occur in a base metal that is of
much lower strength than the weld or other base
metal and when the test specimen might slip in the
bending die. A longitudinal bend specimen makes all
three metals elongate the same amount and in this
case is a better test.
5) In making a transverse bend test for a welding
qualification test, why does a fracture
consistently occur at the centerline of the weld?
This may occur if the base metals and the weld filler
are not fully compatible. Segregation of reaction
products like CrCbN to the centerline may reduce its
strength or ductility. A longitudinal bend test may
hide this problem.
References:
1) Nickel Institute No. 14 014, Pay attention to
dissimilar metal welds
2) Haynes International, Fabrication of
Hastelloy Corrosion-Resistant Alloys
3) Special Metals, Joining Brochure

Contributed by Richard Avery

June 2009

The distribution of MTI documents to non-member companies is done as a service to industry. MTI assumes no responsibility for the contents or for results associated
with implementing any recommendations.
Copyright 2012 Materials Technology Institute, Inc. All Rights Reserved.

TECHNICAL AWARENESS BULLETIN

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GUIDES FOR DISSIMILAR METAL WELDING (DMW)

Table of Filler Consumables for DMW

Filler Metal
Alloy Type

AWS Classification of Shielded Metal

Arc and Bare Wires

1) 309(L) & 312

E309, E309(L), ER309, ER309(L)

E312, ER312
ENi-1, ERNi-1
ENiCu-7, ERNiCu-7
ENiMo-7 & -10, ERNiMo-7 & - 10
ENiCrFe-2, -4, -7, ERNiCr-3 & ERNiCrFe-7, 7A
ENiCrMo-3, -4, -10, -14
ERNiCrMo-3, -4, -10, -14

stainless steel
2) Nickel
3) Nickel-copper
4) Nickel-Molybdenum
5) Ni-Cr-Fe
6) Ni-Cr-Mo

Filler Metal Selection of Various Alloy Families

Stainless - 300,
400, duplex
C.P. Nickel
(Alloy 200, 201)
Ni-Cu alloys
(Alloy 400)
Mi-Mo alloys (B2,B-3,B-4)
Ni-Cr, Ni-Cr-Fe,
Ni-Fe-Cr (alloy
600, 800,825)
Ni-Cr-Mo (alloy
625, C-family

Carbon &
LA steels

Stainless 300, 400,

duplex

C.P.
Nickel

Ni-Cu
alloys

Ni-Mo
alloys

Ni-Cr & NiFe-Cr NiCr-Fe

alloys

1,5

2,5

2,5

5,6

2,3

4,6

2,6

5,6

5,6

5,6

5,6

5,6

Note: Any chromium containing nickel alloy has a somewhat limited tolerance for copper so minimal weld dilution by
copper is advisable. Special buttering techniques may be required to limit weld dilution by copper.
The distribution of MTI documents to non-member companies is done as a service to industry. MTI assumes no responsibility for the contents or for results
associated with implementing any recommendations.
Copyright 2012 Materials Technology Institute, Inc. All
Rights Reserved.

TECHNICAL AWARENESS BULLETIN

Maximizing resources through a global network of materials specialists.

GUIDES FOR DISSIMILAR METAL WELDING (DMW)

The distribution of MTI documents to non-member companies is done as a service to industry. MTI assumes no responsibility for the contents or for results
associated with implementing any recommendations.
Copyright 2012 Materials Technology Institute, Inc. All
Rights Reserved.