Tig Welding Filler Rod Chart

Tig Welding Filler Rod Chart - Two of the settings factors you need to consider when you are using TIG welding is the selection of the filler material and the electrode tungsten within your torch.

Both are significant and we'll focus initially on filler materials.

Through the welding process, TIG you fill the puddle with filler material by using the rod that you carry.

However, those "rods" come in different dimensions and types.

Tig Welding Filler Rod Chart

Knowing which rod to choose and at what time helps make your welding strong and visually pleasing.

With the plethora of options available even experienced welders have to are often challenged to locate the best filler rod.

Therefore to give you a convenience I've listed the answers to the most commonly asked questions as well as suggestions for finding the perfect filler rod.

Do I Need A Filler Rod?

It is likely that you require an filler rod.

However you can fusion-weld using the help of a TIG welder with no filler rod.

However it's only for welding in the following areas:

  • The butt joint that connects the two metal pieces is free of gaps.
  • Base metals are the larger side (e.g. 1/8 inch or more).
  • It will require more heat to melt the metal (which is a risk of burning through).
  • The strength of the weld isn't important (fusion welding is weaker and are generally used to join pieces).
  • This list also outlines the reason why most TIG weldings include the filler rod.

Filler Rod Basics

This filler material is metal alloy that is specifically designed to resist the intense temperature of welds and join parts of the stock to form the composite.

This is why naturally the weight and the alloy of the rods used to fill them vary according to the various thicknesses of stock as well as kinds of base metals that people are welding.

Tig Welding Filler Rod Chart

Filler rods made with TIG typically come in three-foot lengths and are packaged in either 10 or 50 pounds containers or tube.

The diameter is usually between 1-1/4" to 1/8.

Filler rods are composed of various alloys that can handle various metals.

Because the TIG filler rod's composition used is typically similar to that used to make MIG filler a few parts of MIG wires also are used to be used for TIG welding.

Choosing a Filler Rod

There's no final answer on the type of rod to filler you must use for a weld.

But, the weld that you choose to use must meet certain specifications.

This criteria is then applied to determine a set of guidelines.

Manufacturers usually provide detailed charts to assist choose a rod for filling.

In general, the most crucial elements to consider are the thickness of the base metal the composition of it as well as the kind that weld joints are made of.

Based on this criteria it is possible to use specific guidelines to determine those filler rods alloys as well as the diameters that you could want to utilize.

Filler Rod Alloys ("Composition")

The American Welding Society ("AWS") has classified the different alloys and assigned AWS "ER" numbers to make it easier to be able to identify the alloys.

Each number is an "recipe" of chemical additives in the filler metal that deal with specific base metals as well as weld conditions.

The array of alloys available is overwhelming.

Tig Welding Filler Rod Chart

Below, you will find basic guidelines that will help you narrow down the most common components of the rod used to fill.

Additionally, manufacturers often have charts to use to determine the best product for the given welding.


ER70S-2, ER70S-6 and a variety of other options from the ER70S series with different numbers at the end of the line to refer to particular conditions of the metal (e.g. clean or dirty) or the type of joint that is being welded.

The ER70S-6 standard is used to the welding of mild steel.

Stainless Steel

ER308 and ER308L The ER308 and ER308L are two of the most commonly used welding rods.

It's the most popular choice to weld stainless steel 304 that is used extensively in the manufacture of.

Furthermore the filler rod alloy is also used along with other 300-series stainless steels.

ER309 and ER309L is used to join dissimilar metals. It can withstand higher temperatures and is resistant to corrosion.

ER316 and ER316L commonly used for pressure vessels, valves chemical equipment and marine applications.

(The "L" refers to an extra-low carbon content in the rod, which is less than 0.08 percent, which increases resistance to corrosion.)

The above numbers are a few of the most popular however the list of steel-based base materials produced today is a vast array.


The ER4043 is a great general filler material suitable for the majority of aluminum-based applications.

However, welding the 2xxx and 7xxx series of aluminum is usually not recommended.

The ER5356 designation is for 5xxx series aluminum, and is usually preferred when the final product will be anodized.

Chrome Moly Tubing

The ER70S-2 is highly advised to weld 4130 chrome-moly tubing to be used in various applications.

The ER80S-D2 is suggested in welding chrome-moly 4130 tubing, if an increased strength and less ductile weld is required.

If the weld is going to be treated with heat to achieve maximum strength, you should select a filler material that is compatible with the chemical composition of the tubing.

Both the 70S-2 and 80S-2 rods will work here.


When welding Titanium It is generally recommended that the filler rod's alloy to that of the base alloy.

Here are a few most common alloys you might come across:

  • ERTi-2 is best used with titanium grade 2.
  • ERTi-3 is best used with titanium grade 3.
  • ERTi-5 is a great choice for use with titanium grade 5.
  • ERTi-7 - the same mechanical properties as ErTi-2 , but by adding 0.12 percent palladium that gives greater resistance to corrosion. It is resistant to crevices and corrosion caused by under-deposit when the ErTi-2 Titanium wire is not enough. It is suitable as weld Grade 2, or even Grade 16.
  • ERTi-9 as well as ERTi-9ELI, most suitable to use with titanium grade 9.
  • ERTi-23 is best used with titanium grade 23.

Filler Rod Diameter

A thickness measurement of product that you TIG weld can indicate the diameter of the filler rod.

There are a variety of opinions about the correct size of the filler rod.

Below, I've compiled some guidelines to help break out the static.

In general, you should use the filler rod that has dimensions that are less than that of the metal to be welding.

With a metal thickness less than 1/8 inch, rod's diameter should be a little smaller than the metal that is being welding.

To use stainless sheet, select the same size as you would normally use for carbon steel.

This is because you generally utilize less amperage for stainless steel thin stock as compared the carbon steel.

With low amperage rods, large rods chill the puddle, which can result in an unnatural bead.

In the case of aluminum, all guidelines the same rules you'd apply to steel sheet metal are applicable.

According to my experience, 1/16 inch (1.6 mm) wire can be used to make sheets of aluminum that is as thin as 0.040 inches.

For aluminum that is thicker, it can happen that the rod can sag before it even gets to the puddle.

If this happens you can try a smaller arc and a smaller torch angle.

If this doesn't work, try increasing one size using you filler rod.

Additionally, there are many "calculators" online you can make use of.

They can differ slightly between them however, in general they are based on these rules.

Joint Type

The type of welding you do, fillet or butt joint can influence your TIG welding.

It is common to require additional amps (i.e. heat, or amps) when welding fillet joints.

Tig Welding Filler Rod Chart

Additional Considerations

Only use uncoated, bare rods that are specifically made specifically for TIG welding.

Never use electrodes made for shielded metal arc welding ("SMAW") stick welding.

Filler Rod Size And TIG Welder Settings

If you've found the appropriate material for base metal that you intend to weld and not only do you require the correct diameter rod it is also necessary to "dial-in" your welder settings.

The amount of amperage, the gas flow and torch speed and the size of the cup can differ, too.

These guidelines will provide you with a good base for diameter of the rod for filler and welder setting.

However, keep in mind that you might need to alter the settings based on your welding tool and welding method.


The choice of the best TIG filler rod is based on many factors.

The composition of the base metal as well as the joint type, thickness of the stock cleanliness the material as well as the thermal properties of the metal may be a factor in your choice.

It can be confusing at times.

If you follow the tips provided in the article and also if you were in need of some details from manufacturers of filler rods it is possible to zero in on the best option.

Naturally as you gain experience you'll get more comfortable with the rods that best suit the TIG welding method.

Be sure to find the right the correct current (amperage) of the rod.

Additionally make sure to check the gas flow polarity and cup size as well as the speed of the torch.

Before you make an arc.

Then you can begin welding using a particular rod to fill it.

The process of choosing an appropriate filler rod may be daunting at times.

But, with practice and experience it'll become effortless.

It's worth it because knowing the correct variables such as that filler rod will allow you to make strong, stunning TIG welding on a regular basis.

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