Nicorex Alloys is an ISO 9001 and ISO 14001 certified welding consumables supplier in Mumbai, India. We stock filler metals across nickel alloy, stainless steel, duplex, super duplex, chrome-moly, cobalt/Stellite, titanium, aluminium, copper, and zirconium families. These materials cover major welding process from SMAW and GTAW to GMAW, FCAW, and SAW.
Welding consumables are materials consumed during the welding process, such as electrodes, wires, and rods that melt and become part of the finished joint. The filler metal deposited in a weld joint determines whether that joint will outlast the base metal or become the first point of failure. Its chemistry, mechanical properties, and corrosion resistance must match or exceed the base metal being welded. Fluxes and shielding gases protect the molten weld pool from atmospheric contamination.
Our range includes coated electrodes (SMAW) from 2.5 to 5.0 mm diameter, TIG rods from 1.0 to 4.0 mm, MIG spools from 0.8 to 1.6 mm, flux cored wire in 1.2 and 1.6 mm, and SAW wire from 2.0 to 4.0 mm. All available products conform to AWS A5.4, A5.5, A5.7, A5.9, A5.10, A5.11, A5.13, A5.14, A5.16, A5.21, A5.22, A5.28, A5.29, and A5.34 with corresponding ASME SFA equivalents.
Types of Welding Consumables
Welding Electrodes
A welding electrode is a flux-coated rod consumed during shielded metal arc welding (SMAW). The coating provides shielding gas, slag protection, and arc stability in a single package.
MIG and TIG Wire/Rod (GMAW/GTAW)
A welding electrode is a flux-coated rod consumed during shielded metal arc welding (SMAW). The coating provides shielding gas, slag protection, and arc stability in a single package.
Flux Cored Wire (FCAW)
A welding electrode is a flux-coated rod consumed during shielded metal arc welding (SMAW). The coating provides shielding gas, slag protection, and arc stability in a single package.
SAW Wire and Flux
A welding electrode is a flux-coated rod consumed during shielded metal arc welding (SMAW). The coating provides shielding gas, slag protection, and arc stability in a single package.
Welding Consumables Material Grades
Nickel Alloy Welding Consumables
- ERNiCrMo-3 and ENiCrMo-3 for Inconel 625
- ERNiCrMo-4 and ENiCrMo-4 for Hastelloy C276
- ERNiCr-3 and ENiCrFe-3 for Inconel 600/82/182
- ERNiCu-7 and ENiCu-7 for Monel 400
- ERNi-1 and ENi-1 for Nickel 200/201
- ERNiFeCr-1 for Incoloy 800
- ERNiCrMo-10 and ENiCrMo-10 for Hastelloy C22
- ERNiCrMo-13 for Alloy G-30
- ERNiCrCoMo-1 for Inconel 617
- ERNiFeCr-2 for Inconel 718
Stainless Steel Welding Consumables
- ER308L welds 304/304L.
- ER316L matches 316/316L.
- ER309L for carbon to stainless welding
- ER347 serves 321 and 347 stabilised grades.
- ER310 handles high-temperature austenitic service.
- ER385 is the designated filler for 904L.
Duplex and Super Duplex Welding Consumables
- ER2209 and E2209-16 are the standard fillers for Duplex 2205
- ER2594 and E2594-16 match Super Duplex 2507
Chrome Moly Welding Consumables
- E8018-B2/ER80S-B2 for P11
- E9018-B3/ER90S-B3 for P22
- E8018-B6/ER80S-B6 for P5
- E8018-B8/ER80S-B8 for P9
- E9015-B9/ER90S-B9 for P91
Cobalt/Stellite Hardfacing Consumables
- ECoCr-A/ERCoCr-A (Stellite 6)
- ECoCr-B/ERCoCr-B (Stellite 12)
- ECoCr-C/ERCoCr-C (Stellite 1)
- ECoCr-E/ERCoCr-E (Stellite 21)
High-Temperature Alloy Welding Consumables
Nicorex stocks welding consumables for superalloy and high-temperature service. These fillers are designed for oxidation resistance, creep rupture strength, and thermal fatigue performance at 700°C to 1200°C.
- Inconel X750
- Haynes 25
- Haynes 188
- Haynes 230
- Haynes 282
- Waspaloy
- Hastelloy X
Titanium Welding Consumables
Aluminium Welding Consumables
Copper Welding Consumables
Zirconium Welding Consumables
Base Metal to Filler Metal Matching Guide
| Base Metal | UNS | Electrode (SMAW) | Wire (TIG/MIG) | Flux Core | AWS Electrode Spec | AWS Wire Spec |
|---|---|---|---|---|---|---|
| Inconel 600 | N06600 | ENiCrFe-3 | ERNiCr-3 | ENiCr3T1 | A5.11 | A5.14 |
| Inconel 625 | N06625 | ENiCrMo-3 | ERNiCrMo-3 | ENiCrMo3T1 | A5.11 | A5.14 |
| Inconel 718 | N07718 | — | ERNiFeCr-2 | — | — | A5.14 |
| Incoloy 800/800H | N08800 | ENiCrFe-3 | ERNiCr-3 | ENiCr3T1 | A5.11 | A5.14 |
| Incoloy 825 | N08825 | ENiCrMo-3 | ERNiCrMo-3 | — | A5.11 | A5.14 |
| Hastelloy C276 | N10276 | ENiCrMo-4 | ERNiCrMo-4 | — | A5.11 | A5.14 |
| Hastelloy C22 | N06022 | ENiCrMo-10 | ERNiCrMo-10 | — | A5.11 | A5.14 |
| Monel 400 | N04400 | ENiCu-7 | ERNiCu-7 | — | A5.11 | A5.14 |
| Nickel 200/201 | N02200 | ENi-1 | ERNi-1 | — | A5.11 | A5.14 |
| Alloy 20 | N08020 | ENiCrMo-3 | ERNiCrMo-3 | — | A5.11 | A5.14 |
| 304/304L | S30400 | E308L-16 | ER308L | E308LT1 | A5.4 | A5.9 |
| 316/316L | S31600 | E316L-16 | ER316L | E316LT1 | A5.4 | A5.9 |
| 321/347 | S34700 | E347-16 | ER347 | E347T1 | A5.4 | A5.9 |
| Dissimilar CS-SS | — | E309L-16 | ER309L | E309LT1 | A5.4 | A5.9 |
| 904L | N08904 | E385-16 | ER385 | — | A5.4 | A5.9 |
| Duplex 2205 | S31803 | E2209-16 | ER2209 | E2209T1 | A5.4 | A5.9 |
| Super Duplex 2507 | S32750 | E2594-16 | ER2594 | E2594T1 | A5.4 | A5.9 |
| P11 (CrMo) | K11597 | E8018-B2 | ER80S-B2 | E81T1-B2 | A5.5 | A5.28 |
| P22 (CrMo) | K21590 | E9018-B3 | ER90S-B3 | E91T1-B3 | A5.5 | A5.28 |
| P91 (CrMo) | K91560 | E9015-B9 | ER90S-B9 | — | A5.5 | A5.28 |
Welding Consumable Standards and Specifications
| Prefix | Meaning | Example |
|---|---|---|
| E | Electrode (conducts current, SMAW stick) | ENiCrMo-3 |
| R | Rod (does not conduct current, fed into pool) | — |
| ER | Electrode or Rod (dual use: TIG rod or MIG wire) | ERNiCrMo-3, ER308L |
| EC | Electrode Composite (metal cored wire) | EC308L |
| Suffix | Meaning |
|---|---|
| -15 | DCEP only. Deep penetration. Pipe root pass |
| -16 | AC or DCEP. Smooth arc. All position. Most common |
| -17 | AC or DCEP or DCEN. Improved wetting |
| AWS Spec | ASME SFA | Scope | Material | Examples |
|---|---|---|---|---|
| A5.4 | SFA-5.4 | SS coated electrodes | Stainless Steel | E308L-16, E309L-16, E316L-16, E2209-16 |
| A5.9 | SFA-5.9 | SS bare wire and rod | Stainless Steel | ER308L, ER309L, ER316L, ER2209, ER2594 |
| A5.11 | SFA-5.11 | Ni alloy coated electrodes | Nickel Alloys | ENiCrMo-3, ENiCrMo-4, ENiCrFe-3, ENi-1, ENiCu-7 |
| A5.14 | SFA-5.14 | Ni alloy bare wire and rod | Nickel Alloys | ERNiCrMo-3, ERNiCrMo-4, ERNiCr-3, ERNi-1 |
| A5.5 | SFA-5.5 | Low alloy coated electrodes | CrMo | E8018-B2, E9018-B3, E9015-B9 |
| A5.28 | SFA-5.28 | Low alloy wire and rod | CrMo | ER80S-B2, ER90S-B3, ER90S-B9 |
| A5.22 | SFA-5.22 | SS flux cored wire | Stainless Steel | E308LT1-1/4, E309LT1-1/4, E316LT1-1/4 |
| A5.34 | SFA-5.34 | Ni alloy flux cored wire | Nickel Alloys | ENiCrMo3T1-1/4, ENiCr3T1-1/4 |
| A5.29 | SFA-5.29 | Low alloy flux cored wire | CrMo | E81T1-B2, E91T1-B3 |
| A5.13 | SFA-5.13 | Surfacing coated electrodes | Cobalt/Stellite | ECoCr-A, ECoCr-B, ECoCr-C, ECoCr-E |
| A5.21 | SFA-5.21 | Surfacing bare wire and rod | Cobalt/Stellite | ERCoCr-A, ERCoCr-B, ERCoCr-C, ERCoCr-E |
| A5.16 | SFA-5.16 | Ti wire and rod | Titanium | ERTi-1, ERTi-2, ERTi-5, ERTi-7 |
| A5.10 | SFA-5.10 | Al wire and rod | Aluminium | ER4043, ER5356, ER5183 |
| A5.7 | SFA-5.7 | Cu alloy wire and rod | Bronze/Copper | RBCuZn-C, ERCuAl-A2, ERCu, ERCuSi-A |
Get Welding Consumables at Competitive Prices
Which Welding Process Needs Which Consumable?
| Process | Abbreviation | Consumable Form | AWS Spec (Ni) | AWS Spec (SS) | Best For |
|---|---|---|---|---|---|
| Shielded Metal Arc (Stick) | SMAW | Coated electrode | A5.11 | A5.4 | Field repair, all-position, short runs |
| Gas Tungsten Arc (TIG) | GTAW | Bare rod (cut length) | A5.14 | A5.9 | Root pass, thin wall, orbital, highest quality |
| Gas Metal Arc (MIG) | GMAW | Bare wire (spool) | A5.14 | A5.9 | Fill/cap, semi-auto, productivity |
| Flux Cored Arc | FCAW | Tubular flux cored wire | A5.34 | A5.22 | High deposition, windy conditions, all-position |
| Submerged Arc | SAW | Bare wire + granular flux | A5.14+flux | A5.9+flux | Long seams, vessels, cladding |
| Plasma Arc (overlay) | PAW | Bare wire or powder | A5.14 | A5.9 | CRA overlay, precision cladding |
Welding Consumable Storage and Handling
| Consumable Type | Storage Condition | Exposure Limit | Re-Baking |
|---|---|---|---|
| Low-H Electrodes (ENiCrMo, E7018, E8018) | Holding oven 100-150°C | Max 4 hr atmosphere | Re-bake 350–400°C x 1–2 hr |
| Rutile Electrodes (E308L-16, E309L-16) | Dry, below 60% humidity | Sealed packaging | Not required |
| TIG Rod | Dry, sealed tube | Sealed packaging | Not required |
| MIG Wire | Sealed bag with desiccant | Sealed packaging | Not required |
| Flux Core Wire | Sealed, dry storage | Sealed packaging | Not required |
| SAW Flux | Sealed; oven-dry before use | Reseal after opening | Dry per manufacturer spec |
Where are Welding Consumables Used?
- Process Piping Fabrication: Pipe-to-pipe butt welds, pipe-to-fitting joints, and branch connections rely on matched filler metals. ERNiCrMo-3 with a TIG root pass and MIG fill is used in Inconel 625 piping. ER2209 serves duplex systems. ER309L bridges carbon steel to stainless steel transitions. Orbital TIG handles thin-wall heat exchanger tubes.
- Pressure Vessel Fabrication: Shell seam welds (SAW), nozzle welds (SMAW/TIG), and head welds are used. ERNiCrMo-3 SAW covers Inconel vessel long seams at high deposition rates. ER80S-B2 fills P11 CrMo vessels, while E9015-B9 is specified for P91 thick-wall reactors.
- CRA Weld Overlay and Cladding: ERNiCrMo-3 (Inconel 625) overlay protects vessel internals, valve bodies, and pump casings. For stainless cladding, ER309L goes down as the first layer followed by ER316L. Strip cladding via SAW or ESW covers large surface areas at high deposition rates. Weld overlay is the highest-value welding consumable application in process plant fabrication.
- Heat Exchanger Tube-to-Tubesheet Welding: Orbital TIG welding seals tubes into tubesheets with repeatable precision. ERNiCrMo-3 serves Inconel 625 exchangers. ERNiCr-3 handles Inconel 600 units. ER316L covers stainless steel heat exchangers. Precision TIG rods at 1.0 to 1.6 mm diameter and full argon purge on the tube ID are standard practice.
- Maintenance, Repair, and Shutdown Welding: Field repair of corroded piping, worn valve seats, and damaged pump surfaces during plant shutdowns relies on SMAW electrodes because no gas bottles are needed on site. ENiCrMo-3 is the go-to nickel alloy repair electrode. ECoCr-A (Stellite 6) electrodes restore valve seat faces. Quick dispatch from Mumbai stock is critical for turnaround schedules.
- Hardfacing and Wear Overlay: Valve seats on gate and globe valves, pump sleeves, wear rings, and impeller faces are hardfaced with cobalt-base consumables. Stellite 6 (ECoCr-A/ERCoCr-A) is the industry standard for valve disc faces. Stellite 12 provides higher hardness for severe service. Stellite 21 handles high-temperature erosion on valve trim. Cobalt consumables carry a cost premium of 3 to 5 times that of nickel alloy filler per kilogram.
- Dissimilar Metal Welding: Joining different base metals (CS to SS, SS to Inconel, duplex to CS) requires a filler compatible with both sides. ERNiCrMo-3 functions as the universal dissimilar filler for nickel alloy transitions. ER309L serves CS-to-SS joints. Butter layer techniques apply where PWHT-sensitive materials meet at a transition joint in process piping.
How to Order Welding Consumables from Nicorex Alloys
- AWS Classification (e.g., ERNiCrMo-3 per AWS A5.14)
- Product Form: Electrode, TIG Rod, MIG Wire, Flux Core, or SAW Wire
- Diameter: 1.0, 1.2, 1.6, 2.4, 3.2, or 4.0 mm (specify)
- Quantity in kg (specify number of spools, packets, or drums)
- Base metal being welded (for verification)
- Welding process: SMAW, GTAW, GMAW, FCAW, or SAW
- Additional requirements: impact test temperature, NACE compliance, ferrite range, hydrogen designation (H4/H8)
- Documentation: MTC 3.1 per EN 10204, batch certificate, or third-party inspection
- Packaging: standard spool (12.5/15 kg), drum (100–250 kg), TIG rod box (5/10 kg), or electrode packet (2.5/5 kg)
Related Products from Nicorex Alloys
Frequently Asked Questions
What are Welding Consumables?
What Welding Consumables Does Nicorex Alloys Stock in Mumbai?
Which Filler Metal Should I Use for Inconel 625 Pipe Welding?
ERNiCrMo-3 (AWS A5.14) for TIG root and MIG fill passes. ENiCrMo-3 (AWS A5.11) coated electrode for SMAW. The filler carries the same Ni-22Cr-9Mo-3.5Nb chemistry as the base metal. ERNiCrMo-3 also suits welding Incoloy 825, Alloy 20, and dissimilar joints to stainless steel or carbon steel.
What is the Difference Between AWS A5.11 and A5.14?
A5.11 covers nickel alloy coated electrodes for SMAW. A5.14 covers nickel alloy bare wire and rod for TIG, MIG, and SAW. Both specifications share the same alloy chemistry families. The E prefix (ENiCrMo-3) denotes an electrode; the ER prefix (ERNiCrMo-3) denotes a wire or rod. The product form and welding process differ; the deposited weld metal chemistry is equivalent.
What is the Difference Between Consumable and Non-Consumable Electrode?
A consumable electrode melts and becomes part of the weld joint during SMAW, GMAW, and FCAW. A non-consumable electrode does not melt. The tungsten electrode in GTAW only provides the arc; a separate filler rod is hand-fed or machine-fed into the weld pool. Consumable electrodes add filler metal and conduct welding current simultaneously.
Can I Order Matched Consumable Sets for a WPS?
Yes. Example: a P22 WPS set includes ER90S-B3 for TIG root and E9018-B3 for SMAW fill. An Inconel 625 pipe WPS set includes ERNiCrMo-3 TIG wire, ENiCrMo-3 electrode, and ENiCrMo3T1 flux cored wire. Single-source supply from Nicorex keeps all consumables from the same heat and batch for full traceability.