Dissimilar Metal Stainless Wire vs Stick
ER309L wire (MIG/TIG) vs E309L-16 stick for joining stainless to carbon steel. Same chemistry, different process.
Key Differences
| Attribute | ER309L | E309L-16 |
|---|---|---|
| Process | MIG (GMAW) or TIG (GTAW) | Stick (SMAW) |
| Speed | MIG: Fast / TIG: Slow but precise | Moderate |
| Equipment | Wire feeder + gas OR TIG torch | Basic stick welder |
| Joint Access | Needs torch access angle | Rod can reach tight spaces |
| Gas Requirement | MIG: 98/2 or tri-mix / TIG: Argon | Self-shielded by flux |
| Best For | Shop fabrication, pipe welding (TIG) | Field repair, maintenance |
| Cleanup | MIG: None / TIG: None | Slag removal required |
| Weld Chemistry | 23Cr-13Ni (identical) | 23Cr-13Ni (identical) |
Use ER309L when:
Use E309L-16 when:
How ER309L and E309L-16 Work Together
Both deposit 309L chemistry. Choose based on your equipment and joint access. For shop work with good joint access, ER309L MIG is faster. For TIG precision work on piping, ER309L TIG gives the best bead control. For field repairs or tight spaces, E309L-16 stick works anywhere with just a stick welder. On pipe roots, TIG with ER309L is the professional standard. On fill and cap passes, MIG or stick depending on position and access.
Common Mistake With Dissimilar Metal Stainless Wire
Using ER309L MIG wire without proper shielding gas. Stainless MIG requires 98Ar/2CO2 or tri-mix, not the 75/25 Ar/CO2 used for carbon steel. Using 75/25 on stainless causes excessive carbon pickup and poor corrosion resistance.
Where to Buy
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Data sourced from .