ER385 Stainless Steel TIG & MIG Welding Wire Supplier in India
Nicorex Alloys is a Mumbai-based ISO 9001 and ISO 14001 certified supplier and stockist of ER385 welding wire, also known as 904L filler metal. We supply high-quality ER385 Stainless Steel TIG & MIG Welding Wire as classified under AWS A5.9 / ASME SFA-5.9.
ER385 (UNS N08904, EN ISO 14343-A: S 20 25 5 Cu L, Werkstoff Nr. 1.4539) is a super-austenitic stainless steel bare wire and rod with a nominal composition of 20Cr-25Ni-4.5Mo-1.5Cu for GTAW (TIG) and GMAW (MIG) welding of 904L and similar alloys. The weld deposit is fully austenitic with zero ferrite (FN = 0), which demands low heat input and a stringer bead technique to prevent solidification hot cracking. Carbon is held at 0.025% max, silicon at 0.50% max, and phosphorus at 0.020% max to minimise crack-prone low-melting at grain boundaries. Typical all-weld-metal tensile strength reaches 567 MPa (82,200 psi) with 35% elongation. The refined composition of ER385 contains a copper content of 1.2 to 2.0%. The copper-sulphate film formation effectively shields the filler metal from aggressive acid attack. This prevents sulfuric acid corrosion and structural breakdown in the harsh gas or fluid processing systems found in many modern industrial facilities.
TIG rods are available in 1.6, 2.0, 2.4, and 3.2 mm diameters, while MIG spools come in 0.9, 1.0, and 1.2 mm. This filler metal is designed for high-performance compatibility with 904L base metals (ASTM B625/B673/B674/B677) and dissimilar 904L-to-304L/316L joints. To maintain weld integrity, the interpass temperature must not exceed 120°C (250°F). Every consignment is strictly supplied with a Mill Test Certificate 3.1 per EN 10204 for full traceability.
ER385 Welding Wire Specifications
| AWS Classification | ER385 per AWS A5.9 |
|---|---|
| UNS Designation | N08904 |
| Welding Processes | GTAW (TIG), GMAW (MIG), SAW |
| Polarity | GTAW: DCEN; GMAW: DCEP |
| Shielding Gas | GTAW: 100% Argon GMAW: Ar+1–2% O₂ (spray); 90He/7.5Ar/2.5CO₂ (short-circuit) |
| TIG Rod Diameters | 1.6, 2.0, 2.4, 3.2 mm × 1000 mm |
| MIG Wire Diameters | 0.9, 1.0, 1.2 mm |
| MIG Spool Sizes | 5 kg (D200), 12.5/15 kg (D300) |
| SAW Wire | 1.6, 2.4, 3.2 mm on 25 kg coils |
What Does ER385 Mean? - AWS A5.9 Classification Explained
The following table breaks down the technical classification for ER385, highlighting how the addition of Copper and high Molybdenum distinguishes it from standard stainless steel fillers.
| Component | Meaning & Specification | Key Benefit |
|---|---|---|
| ER | Electrode / Rod | Suitable for both MIG (GMAW) and TIG (GTAW) welding processes. |
| 385 | 904L Composition | A unique AWS alloy designation for super-austenitic 20Cr–25Ni chemistry. |
Weld Deposit Chemical Composition of ER385 TIG Welding Rod
| Material / Element | Carbon (C) | Chromium (Cr) | Nickel (Ni) | Molybdenum (Mo) | Copper (Cu) | Manganese (Mn) | Silicon (Si) | Phosphorus (P) | Sulphur (S) | Nitrogen (N) | Iron (Fe) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.9 Requirement (%) | 0.025 max | 19.5–21.5 | 24.0–26.0 | 4.2–5.2 | 1.2–2.0 | 1.0–2.5 | 0.50 max | 0.020 max | 0.030 max | 0.060 max | Balance |
All-Weld-Metal Mechanical Properties of ER385
| Property | Tensile Strength | Yield Strength (0.2%) | Elongation | Hardness |
|---|---|---|---|---|
| Typical Value | 567 MPa (82,200 psi) | 379 MPa (55,000 psi) | 35% | 160–190 HB typical |
Base Metal Compatibility and P-Number Matrix for ER385
| Base Metal | UNS | P-No. | Joint Type |
|---|---|---|---|
| 904L | N08904 | P-45 | Similar (primary) |
| Alloy 20 | N08020 | P-45 | Similar |
| 254 SMO | S31254 | P-8/P-45 | Dissimilar |
| Sanicro 28 | N08028 | P-45 | Similar |
| 317L | S31703 | P-8 | Dissimilar |
| 316L | S31603 | P-8 | Dissimilar |
| 304L | S30403 | P-8 | Dissimilar |
| Carbon Steel | Various | P-1 | Overlay (ER309L buffer first) |
Recommended Welding Parameters for ER385 TIG & MIG Wire
| Rod Dia. | Amps (A) | Volts (V) | Base Thickness |
|---|---|---|---|
| 1.6 mm | 80–150 | ~12 | 1.6–3.2 mm |
| 2.4 mm | 150–250 | ~12 | 3.2–4.8 mm |
| 3.2 mm | 200–375 | ~12 | 6.3–12.7 mm |
| Wire Dia. | Amps (A) | Volts (V) | Gas |
|---|---|---|---|
| 0.9 mm | 170–275 | 23–29 | Ar+1–3% O₂ |
| 1.2 mm | 195–330 | 24–31 | Ar+1–3% O₂ |
Get ER385 Filler Wire at Competitive Prices
Industrial Welding Applications of Stainless Steel ER385 Filler Wire
- For phosphoric acid production, this wire ensures that weld joints in evaporators and transfer piping remain intact even when exposed to extreme thermal cycling and chloride impurities.
- In pharmaceutical and fine chemical manufacturing, it is used for high-purity acid storage and reactor vessels to deliver high-quality, fully austenitic welds that meet strict surface finish standards.
- For pulp and paper bleach plants, it provides the necessary pitting resistance for chlorine dioxide generators and filtrate tanks where standard stainless fillers often fail.
- In oil and gas operations, this alloy resists both general and localised corrosion in sour water strippers and equipment handling ammonia-bearing condensates.
- For desalination and seawater cooling, the combination of molybdenum and copper provides superior protection for brine heaters and piping against warm seawater and crevice corrosion.
- In flue gas desulphurisation, it is utilised for scrubber vessel internals and absorber linings to withstand hot, acidic condensates containing mixed acid concentrations.
Storage and Handling of ER385 (904L) Welding Wire
Available Forms, Diameters and Packaging of ER385 Wire
| Form | Diameters | Packaging |
|---|---|---|
| TIG Rod (GTAW) | 1.6, 2.0, 2.4, 3.2 mm | 5 kg sealed tubes, 1000 mm lengths |
| MIG Spool (GMAW) | 0.9, 1.0, 1.2 mm | 5 kg (D200), 12.5/15 kg (D300) |
| SAW Wire | 1.6, 2.4, 3.2 mm | 25 kg coils |
How to Order ER385 Welding Filler Metal from Nicorex Alloys
- Wire Type - GTAW / GMAW; AWS A5.9 / ASME SFA-5.9: ER385
- Size - GTAW: 1.6, 2.4, 3.2 mm cut lengths; GMAW: 0.9, 1.0, 1.2 mm spools
- Current Type - GTAW: DCEN; GMAW: DCEP, Ar+He+1–3% CO₂ shielding gas
- Welding Position - All positions (1G, 2G, 3G, 4G, 6G)
- Material Grade - 904L; UNS N08904; W.Nr. 1.4539; EN ISO 14343-A: W 20 25 5 Cu N L
- Quantity - GTAW: 5 kg packs; GMAW: D200 / D300 spool - specify count
- Standard - AWS A5.9 / ASME SFA-5.9; EN ISO 14343; ASME Section IX
- Documentation - MTC EN 10204 3.1/3.2; PMI Report; IGC per ASTM A262; TPI certificate
- Packaging - GTAW: rigid plastic tubes/cardboard box; GMAW: vacuum-sealed foil bag with silica gel; export cartons ISPM 15 compliant if international
- Delivery Destination - Domestic / International - specify port or delivery address
Frequently Asked Questions
What is the Price of ER385 TIG and MIG Welding Wire per kg in India?
Why does ER385 Contain Copper, and how does it Help in Sulphuric Acid Service?
Copper at 1.2 to 2.0% forms a copper-sulphate passive film on the weld surface in sulphuric acid. This barrier helps protect against acid damage where Mo-only fillers (ER316L, ER317L) do not work, making ER385 the preferred choice for H₂SO₄ at 20 to 70% concentration up to 80°C.
Can ERNiCrMo-3 (Inconel 625) be used as a Substitute for ER385 when Welding 904L?
Yes, as an over-alloyed alternative for extreme environments or overlay cladding. However, ERNiCrMo-3 costs more and complicates WPS qualification (F-43 vs F-6). For routine 904L joints in sulphuric acid service, ER385 is the correct choice.
Why is Low Heat Input Mandatory when Welding with ER385?
ER385 deposits zero-ferrite weld metal. Without ferrite to absorb low-melting-point, excessive heat inhibits solidification and causes uneven material distribution at the margins, which might crack. Stringers have a 120°C maximum interpass limit crack susceptibility.
What Spool Sizes and TIG Rod Lengths does Nicorex Alloys Stock for ER385?
Is a Buffer Layer Required when Cladding Carbon Steel with ER385 Overlay?
Yes. Deposit ER309L or ER309LMo (minimum 2 layers) on the carbon steel before applying ER385. Direct deposition causes excessive iron dilution, dropping Ni, Mo, and Cu below acid-resistance levels.