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Filler Metal Selection Chart: Carbon Steel

Common stick electrode and MIG wire choices for carbon steel by application, as a starting point before the WPS and code are checked.

Ref WG-0211AWS A5.1AWS A5.18

Draft, open for review. Check every value against the governing standard and the manufacturer’s data before use.

What it is

Most carbon steel welding uses a small family of fillers: a few stick electrodes from AWS A5.1 and solid or metal-cored wires from AWS A5.18, plus flux-cored wires. The right one depends on the process, the condition of the steel, the welding position, the power source and any code. On code work the WPS names the filler, and AWS D1.1 lists matching filler metals for prequalified procedures. Use this chart to narrow choices and ask the right questions.

How to use it

Ask the process and the power source (AC, DC or both).
Ask the position and the steel's condition: clean, mill scale, rusty or painted.
Ask whether there is a WPS or code. If so, it governs.
Pick from the chart, then confirm diameter and package.

Selection chart

Application	Common choice	Why
Pipe root pass, dirty or rusty steel, all positions	E6010 (DCEP)	Deep penetration, fast-freezing, digs through contamination
Same, AC-only machine	E6011	Runs on AC
Sheet metal and light fabrication, good looks	E6013	Soft arc, easy slag, shallow penetration
Structural, code work, crack-sensitive steel	E7018	Low hydrogen, good toughness and strength
Fast flat and horizontal fillets	E7024	High deposition iron powder rod
MIG on clean steel	ER70S-3	Moderate deoxidizers
MIG on mill scale or light rust	ER70S-6	Higher Mn and Si deoxidizers; most common general wire
TIG root passes on steel	ER70S-2	Triple deoxidized; tolerates some contamination
Higher deposition, flat and horizontal	E70C-6M metal-cored	Fast travel, little slag
All-position gas-shielded flux-cored	E71T-1C or E71T-1M	Structural and shop work; match gas to designator
Outdoor, no gas, multipass general	Self-shielded E71T-8 or E71T-11	No gas needed; check the wire's limits on thickness
Outdoor, single pass thin steel	E71T-GS	Single pass only

Key points

Matching strength: 70 ksi fillers suit most mild and common structural steels. Higher-strength steels need fillers chosen per the code.
Low hydrogen rods and wires reduce cracking risk on thick or restrained joints.
E7018 must be kept dry. Follow the maker and the code on storage.
Galvanized and coated steel produce hazardous fumes. Remove coatings and ventilate.

Common mistakes

Using E6013 on structural work.
Running E6010 on an AC machine.
Using GS wire for multipass welds.
Skipping the WPS on code jobs.

Governing standards: AWS A5.1; AWS A5.18; AWS A5.20 and A5.36 (flux-cored); AWS D1.1.

Reference only. Verify against the current governing code or standard, the manufacturer's data and the project documents before use. Apps for Distributors disclaims liability arising from reliance on this reference.

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