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Welding Filler Metal Selection — Quick Reference
Filler metal must match base material + welding process (MIG/TIG/Stick/FCAW). Wrong filler = mechanically + chemically incompatible weld = porosity / cracking / corrosion / failure. Selection by AWS classification + base material grade.
| Filler Metal | Process | Best For |
|---|---|---|
| ER70S-6 (Mild Steel MIG Wire) | MIG | Mild + low-alloy steel — workshop default |
| ER70S-2 (Mild Steel TIG) | TIG | Mild + low-alloy steel general TIG |
| ER308L (Stainless TIG/MIG) | TIG / MIG | 304/304L stainless steel |
| ER316L (Stainless TIG/MIG) | TIG / MIG | 316/316L stainless — marine + chemical |
| ER309L (Dissimilar Stainless) | TIG / MIG | Stainless-to-carbon-steel + dissimilar metal welds |
| ER4043 (Aluminium TIG/MIG) | TIG / MIG | General Al + 6xxx series — silicon for fluidity |
| ER5356 (Aluminium TIG/MIG) | TIG / MIG | 5xxx + 6xxx marine — magnesium for strength |
| E6013 (Stick — General Purpose) | Stick (SMAW) | General fabrication + repair — easy-strike |
| E7016 / E7018 (Low-Hydrogen Stick) | Stick (SMAW) | Structural + high-strength steels — crack-resistant |
| E316L Stick | Stick (SMAW) | Stainless stick welding |
| E71T-1 (Flux-Cored Gas-Shielded) | FCAW | Heavy + outdoor steel structural |
| ERCuSi-A (Silicon Bronze) | TIG (brazing) | Dissimilar metals + brazing + low-heat join |
Critical: Match filler to base — ER70S-6 on stainless = corrosion + cracking; ER308L on mild steel = waste of expensive filler + dilution issues. Low-hydrogen E7016/E7018 stick rods MUST be kept dry (rod ovens or sealed packaging) — moisture = hydrogen embrittlement cracking. Brand: Bossweld. Companion: welding, welding consumables, TIG rods, MIG welding guide.
Welding Filler Metals
Filler metals are the consumable weld material deposited into the joint to form the weld bead. The filler metal must be compatible with the base material and matched to the welding process — MIG (GMAW), TIG (GTAW), flux-core (FCAW), or stick (SMAW). Correct filler metal selection is as important as technique; a filler metal of the wrong specification for the base material produces a weld that may be mechanically inferior, susceptible to cracking, or incompatible with post-weld treatment requirements. AIMS Industrial supplies welding filler metals for carbon steel, stainless steel, and aluminium applications.
MIG Welding Wire (GMAW)
Solid MIG wire for carbon steel applications is typically ER70S-6 — a copper-coated mild steel wire with a deoxidised formulation that tolerates moderate mill scale and surface rust better than ER70S-3. Available in 0.6mm, 0.8mm, 0.9mm, and 1.0mm diameters for different material thicknesses. Wire spool sizes range from 5kg to 15kg; larger spools reduce the frequency of changeovers in production welding but require a drive system capable of handling the weight. Stainless steel MIG wire (ER308L for 304 stainless, ER316L for 316 grade) is fed with a dedicated spool gun or through a stainless-rated liner.
TIG Welding Rod (GTAW)
TIG filler rods are cut-length wire added manually to the weld pool. ER70S-2 or ER70S-6 for mild steel; ER308L, ER309L, or ER316L for stainless steel applications; ER4043 or ER5356 for aluminium. TIG welding demands clean filler — contaminated rod introduces porosity into the weld. Store TIG rods in their original tube and keep them away from moisture, oil, and workshop contamination.
Flux-Core Wire (FCAW)
Flux-core wire allows MIG welding without shielding gas in outdoor and windy conditions where gas coverage cannot be maintained. The flux core provides shielding from within the wire. Gas-shielded flux-core wire (dual-shield) uses both internal flux and external shielding gas for higher deposition rates and better quality welds indoors. Self-shielded flux-core is the correct choice for outdoor structural welding. Flux-core wire produces slag that must be removed between passes.
Order Filler Metals from AIMS
AIMS Industrial stocks welding filler metals for the most common base materials and welding processes. For help selecting the correct filler for your base material and process, contact our team.
Storage and Supply
Proper storage of welding filler metals maintains the product condition needed for consistent weld quality. MIG wire should be kept sealed in its original packaging in a dry environment to prevent oxidation of the copper coating; exposed wire spools should be covered when not in use. TIG rod should remain in its original tube between uses. Low-hydrogen stick electrodes must be stored dry — even brief moisture exposure can cause hydrogen-induced cracking in critical structural welds. AIMS maintains stock of common filler metal specifications for prompt supply.
People Also Ask — Filler Metals
Q: What happens if I use the wrong filler metal for the base material I'm welding?
A mismatched filler produces a mechanically and chemically incompatible weld — porosity, cracking, corrosion or outright failure. Using a mild steel filler like ER70S-6 on stainless causes corrosion and cracking, while using stainless filler like ER308L on mild steel just wastes an expensive filler metal and introduces dilution issues.
Q: What's the difference between self-shielded and gas-shielded flux-core welding wire?
Self-shielded flux-core wire shields the weld entirely from within the wire itself, with no external gas needed — the right choice for outdoor structural welding where wind would blow away gas shielding. Gas-shielded (dual-shield) flux-core wire uses both the internal flux and an external shielding gas, giving higher deposition rates and better weld quality for indoor work.
Q: Why do low-hydrogen stick electrodes like E7016 or E7018 need to be kept dry?
Moisture in a low-hydrogen electrode causes hydrogen-induced cracking in the weld, which is especially critical on structural welds. These electrodes need to be stored dry — in rod ovens or sealed packaging — since even brief moisture exposure can compromise them.
Q: What's the difference between an E6013 and an E7016/E7018 stick electrode?
E6013 is a general-purpose stick electrode for everyday fabrication and repair work, valued for how easily it strikes an arc. E7016 and E7018 are low-hydrogen electrodes built for structural and high-strength steels, where their crack resistance matters more than ease of striking.
Q: What MIG wire diameter should I use for different material thicknesses?
MIG wire is available in 0.6mm, 0.8mm, 0.9mm and 1.0mm diameters, sized to the material thickness being welded. Wire spools also range from 5kg to 15kg — larger spools cut down how often you need to change over in production welding, but need a drive system rated to handle the extra weight.