How to Weld with Hastelloy Filler Wires: Techniques and Best Practices

Hastelloy Filler Wires

When welding with Hastelloy, using the right techniques and equipment to achieve the best results is important. Hastelloy is a popular type of alloy, given its high resistance to corrosion and outstanding strength properties. This makes it suitable for use in different industries, including chemical processing, power generation, and aerospace. This blog post will teach you some essential techniques and best practices for welding with Hastelloy filler wires. Whether you are an experienced welder or a newbie, this information will greatly help you.

What is Hastelloy Filler Wires?

Hastelloy Filler Wires is a type of alloy wire composed of Nickel, Molybdenum, and Chromium for improved corrosion resistance. These wires offer high temperature resistance, good weldability, low thermal expansion values, and durability. They are commonly used in aerospace and chemical processing due to their excellent oxidation resistance.

Advantages of Hastelloy Filler Wire

Excellent Corrosion Resistance of Hastelloy Filler Wires

Hastelloy filler wire is an alloy that offers excellent resistance to corrosion in a wide range of environments. The alloy is particularly resistant to pitting and crevice corrosion, making it an ideal choice for chemical processing and other industries with corrosive chemicals.

Good Weldability

Hastelloy filler wire also has good weldability, which can be easily joined to other metals using welding techniques. This makes it an ideal choice for applications where two or more metals must be joined together.

High Temperature Resistance

Hastelloy filler wire can also withstand high temperatures without losing strength or becoming brittle. This makes it an ideal choice for use in high temperature applications such as furnaces or boilers.

Low Maintenance

Hastelloy filler wire is a low maintenance alloy that does not require regular cleaning or maintenance to keep it functioning properly. This makes it an ideal choice in applications where regular maintenance would be difficult or impractical.


Hastelloy filler wire is a versatile alloy that can be used in various applications due to its combination of properties. This makes it an ideal choice for many industries and applications.

How to Weld with Hastelloy Filler Wires: Techniques and Best Practices

Select the Right Hastelloy Filler Wires

When welding with Hastelloy, the first step is to pick the right filler wire. Different types of filler wires are available, including Hastelloy B-2, C-22, C-276, and X. Each of these wires is designed for specific welding applications. For instance, Hastelloy C-276 is ideal for welding in corrosive environments, while B-2 is suitable for chemical processing applications. Before choosing a filler wire, it is important to consider the type of environment and the expected outcome of the welding project.

Proper Preparation

Welding with Hastelloy also requires proper preparation to ensure the weld zone is clean and free of contaminants. Before welding, you should ensure that the surface to be welded is clean and free of rust, dirt, oil, or any other contaminants that may affect the quality of the weld. You can use a wire brush or pre-cleaning solution to clean the surface.

Use the Right Equipment

Using the right equipment is crucial when welding with Hastelloy filler wires. The welding equipment must be designed to handle the high-temperature conditions associated with Hastelloy welding. This includes a good quality TIG welding machine that is capable of reaching high temperatures. You should also ensure that the welding torch, tungsten, and shielding gas are all suitable for Hastelloy welding.

Welding Techniques

When welding Hastelloy, it is recommended to use DC reverse polarity, as this will help to ensure a stable arc and produce a cleaner weld. You should also use a low welding current to prevent burn-through and distortion. Additionally, using a consistent travel speed to produce a uniform weld bead is important. Hastelloy welding requires patience and attention to detail, so take your time and do not rush the process.

Post-Weld Treatment

Once welding is complete, it is important to perform post-weld treatment to ensure that the weld zone is protected from any potential corrosion. This treatment usually involves cleaning the weld zone and applying passivation treatment. You can use a nitric acid or citric acid solution to passivate the weld zone and reduce the risk of corrosion.


In conclusion, welding with Hastelloy filler wires requires a careful approach and attention to detail. By following these essential techniques and best practices, you can ensure that your welding project is successful and achieves the desired results. Always pick the right filler wire, prepare the surface properly, use the right equipment, follow proper welding techniques, and perform post-weld treatment. With these tips, you can achieve a clean, high-quality weld with Hastelloy.