How to Weld with Hastelloy Welding Electrodes

Hastelloy Welding Electrodes

Welding is a critical process in various industries, including aerospace, chemical processing, and energy industries. It requires excellent technical skills to perform the task seamlessly, especially when working with high-performance materials like Hastelloy. Hastelloy is a unique alloy with exceptional corrosion resistance, thermal stability, and durability, making it ideal for use in challenging environments. This article will discuss how to weld with Hastelloy welding electrodes, the techniques involved, and the best practices for a successful welding process. Whether you are a beginner or an experienced welder seeking to improve your skills, stick around for an informative read!

What is Hastelloy Welding Electrodes?

Hastelloy Welding Electrodes are special electrodes made up of a nickel based alloy that is highly resistant to corrosion and oxidation. They are used in welding and fabrication applications involving heavy alloys like stainless steel, titanium and copper. The main advantage of using these electrodes is their ability to provide stronger welds with greater resistance against high-temperature applications.

Understanding Hastelloy Welding Electrodes

Before we dive into the welding techniques, it’s essential to understand the Hastelloy welding electrodes’ various types and properties. Hastelloy welding rods are available in various grades, such as Hastelloy C-22 and Hastelloy C-276. These alloys have high nickel and chromium content, making them heat and corrosion-resistant. The welding electrode selection depends on the specific Hastelloy grade and the application.

The Welding Techniques

The welding technique is crucial in achieving a quality weld. When welding with Hastelloy, it’s essential to use low heat input to prevent warping, cracking, and distortion. The Tungsten Inert Gas (TIG) welding process is the most common technique to weld Hastelloy. This process uses a non-consumable tungsten electrode to create the weld puddle, filled using the Hastelloy filler metal. It’s important to note that Hastelloy alloys have a low thermal conductivity, making them prone to heat build-up, which can cause distortion. Therefore, it’s essential to control the heat input using proper amps and voltage settings.

Pre-Welding Preparation

Proper preparation before welding is critical in achieving high-quality welds. The first step is to clean the workpiece’s surface, removing any dirt, oil, or contaminants that can interfere with welding. Next, it’s essential to track the parts, aligning them correctly before starting the welding process.

Ensure a fully enclosed area is used, and air vents and all other gaps, including those between metal sheets, are covered with taped-up cloth. This helps prevent the trapping of dust and other particles within the area and full heat entrapment.

Tips for a successful welding process

As mentioned, controlling the heat input is crucial in Hastelloy welding. Be sure to adjust your amps and voltage settings accordingly.

  1. Use a steady hand to avoid shaking and instability during the welding process.
  2. Use filler metal that matches the specific Hastelloy grade being welded and ensure proper storage to prevent contamination.
  3. Regularly clean your equipment, including the TIG torch and tungsten electrode, to prevent contamination.
  4. Patience is a virtue! Hastelloy welding requires slow and steady welding using a skilled hand, so take your time, and the results will speak for themselves.


Welding with Hastelloy requires precision, skill, and adherence to best practices. You can achieve quality welds by understanding the various Hastelloy welding electrodes, selecting the appropriate welding technique, and following the right preparation procedures. Remember, Hastelloy alloys are robust and are widely used in demanding applications, so taking your time to carefully select your equipment and welding procedure will only lead to an exceptional end product.