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Filler Metal
The metal added to the weld joint during fusion welding, typically in the form of wire or electrode. Filler metal must be compatible with the base metal chemistry and meet the mechanical property requirements of the application.
Filler metal must be chemically matched to the base metal to prevent brittle intermetallic phases and embrittlement in the fusion zone and heat-affected zone. For instance, austenitic stainless steel filler must be selected to prevent sensitization and intergranular corrosion, while filler metal for high-strength structural steel must match or exceed the tensile and yield properties of the parent material.
The diameter, deposition rate, and shielding characteristics of the filler depend on the welding process, GMAW solid wire differs fundamentally from FCAW tubular wire in how it responds to heat input and moisture. Proper storage and handling of filler materials, especially low-hydrogen electrodes, prevents hydrogen uptake and associated delayed cracking in susceptible alloys.
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