AWS Class E385-16 Welding Electrodes
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E385-16 (904L) Super Austenitic Stainless Steel Welding Electrode Supplier in Mumbai
Nicorex Alloys is a Mumbai-based, ISO 9001 and ISO 14001-certified leader in the supply, import, and stocking of E385-16 (904L) Super Austenitic Stainless Steel Welding Electrodes. We offer electrodes that meet AWS A5.4 / ASME SFA 5.4 standards for quick delivery to India’s chemical, fertiliser, and heavy process industries.
E385-16 (904L) is a high-alloy, low-carbon electrode providing exceptional resistance to sulfuric acid and chloride-induced pitting in severe environments. The rutile coating on this UNS W88904 electrode provides compatibility with the 904L stainless steel and the 20Cr-25Ni-4.5Mo-1.5Cu alloy system, which has been qualified to ASME standards. E385-16 (904L) Super Austenitic Stainless Steel Welding Electrodes consist of 20.5% chromium, 25.2% nickel, 4.6% molybdenum, and 1.7% copper, a combination that provides superior resistance to acidic environments. The mechanical properties of the weld deposit are a tensile strength of 610 MPa (88,400 psi) and a yield strength of 450 MPa (65,200 psi), with 32% elongation. The weld deposit is totally austenitic (FN 0); hence, stringer bead procedures with an interpass temperature below 100°C are needed to minimise solidification cracking and maintain equipment integrity in chloride-corrosive conditions. In aggressive environments containing sulfuric and phosphoric acids, E385-16 (904L) electrodes provide essential corrosion resistance due to their molybdenum-copper constituents.
Available in 2.4 mm, 3.2 mm, 4.0 mm, and 4.8 mm diameters at 350 mm lengths, these rods work in all positions except vertical down on AC or DCEP. The base metal used is 904L (P-45). This alloy is essential for the chemical, fertiliser, pulp and paper, seawater cooling, and pharmaceutical industries. To guarantee quality, we supply every batch with full EN 10204 3.1 MTC certification.
E385-16 Electrode Specifications
These specifications and code classifications are given in the following table for E385-16 super austenitic coated electrodes for SMAW applications:
| AWS Classification | E385-16 |
|---|---|
| ASME SFA Specification | SFA 5.4 |
| UNS Number | W88904 |
| Welding Process | SMAW (Shielded Metal Arc Welding) |
| Coating Type | Rutile (Titania, -16 designation) |
| Polarity / Current | AC or DCEP (DC+ preferred) |
| Welding Positions | All positions except vertical-down |
| Available Diameters | 2.4 mm (3/32″), 3.2 mm (1/8″), 4.0 mm (5/32″), 4.8 mm (3/16″) |
| Electrode Length | 350 mm (14″) |
Decoding E385-16 - What the AWS A5.4 Classification Tells You
The table below lists the stainless steel electrode AWS A5.4 alphanumeric classification. Procurement and welding professionals receive real-time deposit, chemical, and electrode data from this system.
AWS A5.4 Classification Breakdown for E385-16
| Designation | Technical Significance | Engineering Specification |
|---|---|---|
| E | Electrode | This electrode is specifically designed for shielded metal arc welding (SMAW). |
| 385 | Weld Deposit Type | Matches 904L super austenitic chemistry (20Cr−25Ni−4.5Mo−1.5Cu). |
| -16 | Coating & Current | Rutile (titania) coating supports AC or DCEP in all positions. |
| Carbon Limit | ≤0.03% | The design is low-carbon to prevent sensitisation. |
| Microstructure | Fully Austenitic | The zero delta ferrite requires stringent control of phosphorus and sulfur to avoid hot cracking. |
The American Welding Society devised the “385” number to designate the 904L filler metal system. E385-16 has the molybdenum and copper balance needed for severe sulphuric acid duty, unlike E317L-16, which lacks copper, and E320LR-16, which targets Alloy 20.
Chemical Composition of E385-16 Weld Deposit (%)
Refer to the following table for E385-16 as per AWS A5.4 / ASME SFA 5.4 weld deposit chemistry, specific to all-weld-metal analysis.
| Element | Carbon (C) | Chromium (Cr) | Nickel (Ni) | Molybdenum (Mo) | Copper (Cu) | Manganese (Mn) | Silicon (Si) | Phosphorus (P) | Sulfur (S) | Iron (Fe) |
|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.4 Range | 0.03 max | 19.5–21.5 | 24.0–26.0 | 4.2–5.2 | 1.2–2.0 | 1.0–2.5 | 0.90 max | 0.03 max | 0.02 max | Balance |
| Typical Deposit | 0.015 | 20.5 | 25.2 | 4.6 | 1.70 | 2.1 | 0.45 | 0.018 | 0.009 | Balance |
E385’s defining elements are 4.5% Mo and 1.5% Cu. Mo resists pitting and crevice corrosion in chloride environments; Cu resists reducing acids, especially sulfuric acid at 5–60%. Minimising hot cracking risk in completely austenitic zero-ferrite deposits requires ultra-low carbon (0.03% max, generally 0.015%) and regulated P and S (0.03% max, 0.02% max). Dilution from the base metal impacts service deposit chemistry.
All-Weld-Metal Mechanical Properties of E385-16
These mechanical properties represent all-weld-metal test results per AWS A5.4. Values are for the weld deposit.
| Condition | Ultimate Tensile Strength | Yield Strength (0.2%) | Elongation (%) | Charpy V-Notch Impact | Ferrite Number | Hardness |
|---|---|---|---|---|---|---|
| AWS A5.4 Minimum | 75,000 psi (520 MPa) | Not specified | 30% min | Not applicable | — | — |
| Typical Values | 88,400 psi (610 MPa) | 65,200 psi (450 MPa) | 32% | — | FN 0 (fully austenitic) | ~90 HRB typical |
The fully austenitic deposit achieves 32% elongation combined with UTS exceeding the AWS minimum by over 17%. The zero-ferrite microstructure provides excellent impact toughness at cryogenic temperatures, making E385 deposits suitable for non-magnetic and low-temperature applications beyond standard corrosive chemical service.
Base Metal Compatibility & ASME P-Number Matrix for E385-16
E385-16 is the primary filler for 904L and related super austenitic alloys. The table below covers both similar-metal joints and dissimilar-metal transitions.
Similar Metal Joints:
| Base Metal | UNS | ASME P-No. | Notes |
|---|---|---|---|
| 904L | N08904 | P-45 | Primary match |
| 254 SMO | S31254 | P-45 | Super austenitic |
| AL-6XN | N08367 | P-45 | Super austenitic |
Dissimilar Metal Applications:
| Joining Application | Base Metal Compatibility | ASME P-Number | Technical Requirement |
|---|---|---|---|
| Dissimilar Transition | 904L to 317L Stainless Steel | P-8 | Bridges standard and high-alloy piping systems. |
| Corrosion Overlay | Carbon or Low-Alloy Steel | P-1 / P-3 | Requires E309LMo buffer layer to manage alloy dilution. |
| Performance Upgrade | E317L-16 Substitution | — | Enhances resistance in specific reducing-acid environments. |
Critical: Dilution from carbon steel base metal into the fully austenitic E385 deposit can reduce Mo and Cu below corrosion-resistant thresholds. Multi-layer cladding with controlled heat input is essential for all overlay applications.
Recommended Welding Parameters for E385-16 Electrode
Low heat input is mandatory for E385-16. The fully austenitic zero-ferrite deposit is highly susceptible to solidification cracking, which is why strict adherence to these parameters is essential.
| Diameter (mm/in) | Flat (A) / V & OH (A) | Voltage (V) / Polarity |
|---|---|---|
| 2.4 mm (3/32″) | 70–85 / 65–75 | 24–28 V / AC or DCEP (DC+ pref.) |
| 3.2 mm (1/8″) | 85–110 / 80–90 | 26–30 V / AC or DCEP |
| 4.0 mm (5/32″) | 110–140 / 100–120 | 28–32 V / AC or DCEP |
| 4.8 mm (3/16″) | 120–160 / 110–130 | 28–32 V / AC or DCEP |
Critical procedure requirements:
- Stringer beads only – no weaving. The zero-ferrite deposit cracks under excessive heat input.
- Interpass temperature: 100°C (212°F) maximum – lower than standard 300-series practice due to hot cracking sensitivity.
- Preheat: not required for 904L base metal. Avoid preheating.
- Heat input: <1.0 kJ/mm (25 kJ/in) recommended.
- Re-dry electrodes at 300°C (570°F) for 1 hour before use.
- DC+ (DCEP) preferred over AC for better puddle control and reduced porosity.
- Maintain brisk travel speed to minimise puddle residence time.
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Corrosive-Service Welding Applications of E385-16 Electrode
The following are the applications in which the E385-16 Electrode are widely used:
- In sulfuric and acetic acid reactors, E385-16 is used to ensure weld deposits survive where standard 316L joints typically fail under pressure.
- Linking 904L vessels and agitator shafts in fertiliser plants, this electrode is essential because its chemistry prevents failure at 80°C
- Applied in bleach towers and wash filters, as needed to stop pitting in chloride-heavy settings where lower-alloy steels fail.
- Used in desalination plants and coastal stations, it prevents chloride pitting in warm seawater, protecting systems where 316L joints typically fail within three years.
- Ideal for process vessels and MRI equipment, the fully austenitic, non-magnetic deposit resists aggressive cleaning media.
Storage, Handling & Reconditioning of E385-16 Electrodes
E385-16 should be kept sealed between 15 and 25°C and below 50% humidity. Place in a 100–150°C oven soon after opening. Before usage, re-dry at 300°C (570°F) for 1 hour. Moisture control is essential to minimise porosity and maintain weld metal integrity.
Re-baking is limited to 2–3 cycles maximum. In humid environments (>50% RH), use the electrode within 2 hours of oven removal; 4 hours maximum in controlled workshops. Sealed shelf life is 3-5 years; 6 months once opened with proper storage.
Available Forms & Packaging - E385-16 Electrode
The following is a detailed table showing the information for available forms and packaging specimens for E385-16 Electrode
| Product Form | Diameter (mm) | Standard Length / Packaging | Specification |
|---|---|---|---|
| SMAW Electrodes | 2.4, 3.2, 4.0, 4.8 | 350 mm Length; Hermetically sealed cans (2.5/5.0 kg) or Vacuum-packed cartons | E385-16 |
| TIG Straight Rods | 1.6, 2.4, 3.2 | 1000 mm Length; 5 kg plastic tubes | ER385 |
| MIG Wire | 0.9, 1.0, 1.2 | Precision layer wound on D200 or D300 spools | ER385 |
| Trial Packs | Per request | 1 lb (0.45 kg) tubes available for welding procedure qualification (WPQ) | E385/ER385 |
How to Order E385-16 Welding Electrode from Nicorex Alloys
Please provide the following 10 details to procure E385-16 Welding Electrode from Nicorex Alloys
- Electrode Type: SMAW Covered Electrode / Stick (E347-16)
- Size: 2.5mm / 3.2mm / 4.0mm / 4.8mm x 350mm
- Current Type: DCEP or AC — specify amperage per diameter
- Welding Position: Flat & Horizontal preferred; specify if all-position welding is required
- Material Grade: 904L Super-Austenitic (UNS W88904 / AWS A5.4: E385-16 / W.Nr. 1.4539)
- Quantity: Available in standard packs of 1 kg / 5 kg / 10 kg / 20 kg
- Standard: AWS A5.4 / ASME SFA 5.4 (E385-16), EN ISO 14343, ASME Section IX
- Documentation: MTC EN 10204 3.1/3.2, PMI, Weld Metal Composition, Mechanical Properties, and IGC Test Reports
- Packaging: Hermetically sealed tin canisters / vacuum foil packs; ISPM 15 compliant export cartons
- Delivery: Domestic / International (specify destination)
Frequently Asked Questions
Why is E385-16 called a "904L" welding electrode?
AWS “385” was established for filler metals that match 904L (UNS N08904) super austenitic stainless steel deposit chemistry. “385” is a unique AWS designation for this high-alloy 20Cr-25Ni-4.5Mo-1.5Cu composition.
What is the maximum interpass temperature when welding with E385-16?
The E385-16 can only reach 100°C or 212°F, compared to 175°C for conventional austenitic stainless steel electrodes. The totally austenitic zero ferrite weld deposit cracks upon solidification at too high a temperature; strict monitoring is needed. Make no exceptions for production welds.
Can E385-16 be used to clad carbon steel vessels?
Yes. E385-16 is widely used for cladding carbon steel vessels with a 904L overlay. A buffer layer of E309LMo is recommended for the first pass to manage dilution. Multiple layers with a strict low-heat-input technique are required to achieve full 904L corrosion resistance at the final overlay surface.
What is the difference between E385-16 and E320LR-16?
E385-16 deposits ~20Cr-25Ni-4.5Mo-1.5Cu for 904L, whereas E320LR-16 deposits ~20Cr-33Ni-2.5Mo-3.5Cu for Alloy 20. E385 has greater molybdenum for chloride pitting resistance, while E320LR has higher copper and nickel for improved reducing acid coverage. Base metal and process corrosion environment determine selection.
Does E385-16 meet ASTM G48 pitting corrosion test requirements?
Yes. Properly deposited E385-16 weld metal passes ASTM G48 Method A (ferric chloride pitting test) at 40°C, confirming resistance to chloride-induced pitting. Test certificates are available on request from Nicorex Alloys.
Can E385-16 substitute for E317L-16 in sulfuric acid service?
Yes. E385-16 resists sulfuric acid better due to more molybdenum (4.5% vs. 3.5%) and copper (1.7%). E317L deposits degrade over 20% in sulfuric acid, although E385 deposits survive up to 60%.