AWS A5.9 / ASME SFA-5.9 · Duplex MIG wire & TIG rod (GMAW / GTAW)

ER2209 Duplex MIG Wire and TIG Rod

ER2209 is a duplex stainless steel bare wire or rod classified to AWS A5.9 for MIG and TIG welding of 22 % chromium duplex stainless steels such as 2205 and UNS S31803, depositing a balanced ferritic-austenitic weld metal at roughly 22.5 % chromium, 8 % nickel and 3 % molybdenum with approximately 55 FN ferrite, typically giving 550 to 660 MPa yield — around half as strong again as a 316L deposit — with high resistance to chloride pitting and stress corrosion cracking.

Duplex stainless steel, 2205 / UNS S31803 / S32205
Duplex MIG wire & TIG rod (GMAW / GTAW)
EN ISO 14343-A
4 ESAB grades

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Price on request. POFIS is an ESAB Authorized Distributor & Service Centre in Abu Dhabi — quotations include confirmed lead time and delivery terms.

The designation

What ER2209 means

ER: A bare electrode or rod under AWS A5.9, fed as MIG wire or cut as TIG rod. The covered stick electrode equivalent is E2209 under AWS A5.4.
22: Nominal chromium content, around 22.5 %. Higher than the 18 to 20 % of an austenitic grade, and the main contributor to corrosion resistance.
09: Nominal nickel content, around 8 %. Deliberately lower than an austenitic grade, because a duplex structure needs roughly half its volume to remain ferrite — but still above the 2205 parent, so the weld forms enough austenite as it cools.
Mo + N: About 3 % molybdenum and a controlled nitrogen addition. Nitrogen is both a strong austenite former and counts three times as heavily as molybdenum in the PRE calculation, which is why duplex root runs are backed with nitrogen rather than argon.
FN: Ferrite number, the measured ferrite content of the deposit. ESAB publishes approximately 55 FN for the Exaton duplex wires. Every duplex procedure specifies an acceptance range, commonly around 30 to 70 FN depending on the client specification.

Reading the ER2209 designation, left to right.

How it behaves

ER2209 in practice

Why the wire is richer in nickel than the plate

The 2205 parent arrives with its ferrite-austenite balance fixed by the mill's solution anneal. The weld gets no such treatment: it solidifies fully ferritic and forms austenite only as it cools, so a matching composition would finish too ferritic and lose both toughness and corrosion resistance. ER2209 is deliberately over-alloyed in nickel to drive austenite formation during cooling, which is what lets a duplex weld reach a balanced structure without post-weld heat treatment.

Heat input has a floor as well as a ceiling

This is what catches people coming from austenitic work. Too little heat input cools the weld too fast and leaves excess ferrite; too much, or too high an interpass, allows sigma and other intermetallics to precipitate, destroying toughness and corrosion resistance. ESAB gives 5 to 25 kJ/cm for duplex with a favourable cooling time of t12/8 = 8 to 10 seconds, and an interpass ceiling of 250 °C for duplex — the widely quoted 150 °C figure is the lean and super duplex limit, not the 2205 one.

Nitrogen backing is a real requirement

Nitrogen can be lost from the root pool to the atmosphere, and losing it costs both austenite formation and pitting resistance. ESAB recommends pure nitrogen as the backing gas for duplex, and lists N2 among the shielding options for its duplex TIG grades. On site this is routinely substituted with argon because argon is what is on the trolley, and the loss does not surface until corrosion testing.

The ferrite number is the acceptance criterion

Duplex procedures specify a ferrite range in the finished weld and verify it by ferrite meter or metallographic count. ESAB publishes approximately 55 FN for the Exaton duplex wires — a figure the stick electrodes in this range do not publish. Agree the method and the acceptance limits with the client before the first bead, because a weld outside the range cannot be corrected by rework.

Why duplex rather than 316L

Roughly twice the yield strength, substantially better chloride pitting resistance, and — critically — resistance to chloride stress corrosion cracking, which austenitic grades are genuinely vulnerable to in warm chloride service. For produced water, seawater injection, firewater and process pipework in the Gulf, that combination lets a designer specify thinner walls in a more aggressive fluid. It is why duplex runs through UAE oil and gas specifications.

What POFIS supplies

ESAB ER2209 grades

Every grade below carries the ER2209 classification, which is why a WPS naming ER2209 can be satisfied by any of them. They are not interchangeable in practice — the differences in current type, hydrogen level and impact toughness are what decide which one belongs on your job. Figures are the manufacturer's typical as-welded values.

**ER2209 grades supplied by POFIS** — typical as-welded properties. Blank cells are values the manufacturer does not publish for that grade, not zeros.
Grade	Classification	Yield	Tensile	Elong.	Impact (lowest published)
Exaton 22.8.3.L (GTAW) POFIS recommends	ER2209 (AWS A5.9)	580 MPa	710 MPa	28 %	160 J at −40 °C
Exaton 22.8.3.LSi (GMAW)	ER2209 (AWS A5.9)	630 MPa	810 MPa	32 %	145 J at −30 °C
OK Autrod 2209	ER2209 (AWS A5.9)	590 MPa	785 MPa	31 %	90 J at −46 °C
Exaton 22.8.3.L (GMAW)	ER2209 (AWS A5.9)	550 MPa	770 MPa	30 %	100 J at −40 °C

Exaton 22.8.3.L (GTAW) ER2209 (AWS A5.9)

By far the toughest grade here: 200 J at room temperature, 180 J at −20 °C and 160 J at −40 °C. ESAB lists I1, I2, I3 and N2 shielding, the nitrogen-bearing option being what a duplex procedure usually calls for. Approximately 55 FN.

Alloy type: Austenitic-ferritic duplex, approx. 55 FN — 22.5 % Cr, 8 % Ni, 3 % Mo, low C
Type: TIG rod (GTAW), shielding I1 / I2 / I3 / N2
Source: ESAB Filler Metal Handbook, page 4-137

Exaton 22.8.3.LSi (GMAW) ER2209 (AWS A5.9)

The strongest MIG grade at 630 MPa yield and 810 MPa tensile, with 150 J at room temperature and 145 J at −30 °C. Silicon improves wetting, which matters more on duplex than on austenitic because the pool is less fluid. Approximately 55 FN.

Diameters: 0.8 mm, 1.0 mm, 1.2 mm
Alloy type: Austenitic-ferritic duplex, approx. 55 FN — 22.5 % Cr, 8 % Ni, 3 % Mo, low C
Type: Solid MIG wire (GMAW), shielding M12 / M13
Source: ESAB Filler Metal Handbook, page 4-112

OK Autrod 2209 ER2209 (AWS A5.9)

The standard MIG wire, 0.8 mm to 1.6 mm, at 590 MPa yield and 785 MPa tensile with 105 J at −30 °C and 90 J at −46 °C. Named in ESAB's own worked ferrite example against 1.4462 parent.

Diameters: 0.8 mm, 1.0 mm, 1.2 mm, 1.6 mm
Alloy type: Austenitic-ferritic — 22.5 % Cr, 8 % Ni, 3 % Mo, low C
Type: Solid MIG wire (GMAW), shielding M12 / M13
Source: ESAB Filler Metal Handbook, page 4-79

Exaton 22.8.3.L (GMAW) ER2209 (AWS A5.9)

The plain MIG wire without added silicon, for procedures that limit it. 0.8 mm to 1.6 mm, 550 MPa yield, holding 100 J at −40 °C. Approximately 55 FN.

Diameters: 0.8 mm, 1.0 mm, 1.2 mm, 1.6 mm
Alloy type: Austenitic-ferritic duplex, approx. 55 FN — 22.5 % Cr, 8 % Ni, 3 % Mo, low C
Type: Solid MIG wire (GMAW), shielding M12 / M13
Source: ESAB Filler Metal Handbook, page 4-110

Diameters are listed from the manufacturer's deposition data. Ordering part numbers and pack sizes are confirmed with your quotation — send the grade and diameters you need to weldiv@pofis.ae.

Specifying

Which ER2209 grade to specify

For general MIG welding of 2205

Exaton 22.8.3.LSi is the strongest MIG grade here at 630 MPa yield and 810 MPa tensile, with 150 J at room temperature and 145 J at −30 °C, approximately 55 FN, in 0.8 mm to 1.2 mm. The silicon addition improves wetting, which on duplex matters more than on austenitic because the pool is less fluid.

Where a procedure limits silicon

Exaton 22.8.3.L is the plain MIG wire at 550 MPa yield and 770 MPa tensile, holding 100 J at −40 °C, approximately 55 FN, 0.8 mm to 1.6 mm. OK Autrod 2209 is the alternative at 590 MPa yield and 785 MPa tensile with 90 J at −46 °C, in the same diameter range.

For TIG roots — and this is where duplex work is won or lost

Exaton 22.8.3.L in TIG form gives by far the best toughness on this page: 200 J at room temperature, 180 J at −20 °C and 160 J at −40 °C. ESAB lists I1, I2, I3 and N2 among its shielding options, the nitrogen-bearing choice being the one a duplex procedure usually calls for. For a root run that has to meet both an impact requirement and a ferrite acceptance range, start here.

Matching the stick electrodes

Where a joint is TIG-rooted and stick-filled — common on duplex pipework — the wire and electrode must both satisfy the procedure. The E2209 stick hub covers OK 67.50, OK 67.55 and the Exaton 22.9.3 pair. ESAB's own worked ferrite example uses OK 67.50 with OK Autrod 2209 and OK Tigrod 2209 against 1.4462 parent, so that combination is documented by the manufacturer.

When super duplex is required

Grades such as 2507 and UNS S32750 run higher chromium, molybdenum and nitrogen and reach PRE 40 or above. They are welded with ER2594, not ER2209 — a duplex deposit on super duplex parent would have a lower PRE than the material around it, making the weld the first thing to corrode in exactly the service the parent was specified to survive.

Storage & handling

Storing and handling ER2209 consumables

Agree the ferrite range before welding

Duplex procedures specify an acceptable ferrite range, typically around 30 to 70 FN depending on the specification, verified by ferrite meter or metallographic count. Settle the method and the limits with the client before the first bead. POFIS supplies ferrite measurement instrumentation alongside the consumables.

Clean before passivating

Heat tint on a duplex weld is chromium-depleted scale over chromium-depleted metal, and in the chloride service duplex is chosen for, that band corrodes first. Pickle and passivate with chemistry rated for duplex rather than generic stainless product, and use manual brushing in preference to mechanical to avoid forming grooves that become crevice corrosion sites.

Frequently asked

ER2209 — common questions

What wire is used to weld 2205 duplex stainless steel?

ER2209 under AWS A5.9, as MIG wire or TIG rod. It is deliberately richer in nickel than the 2205 parent, because duplex weld metal solidifies fully ferritic and forms austenite only during cooling — the extra nickel drives that austenite formation so the deposit reaches a balanced structure without post-weld heat treatment. The covered electrode equivalent is E2209 under A5.4.

What ferrite number should a 2209 weld have?

ESAB publishes approximately 55 FN for its Exaton duplex wires. The acceptance range for a given job comes from the client specification, commonly around 30 to 70 FN, verified by ferrite meter or metallographic count. Agree the method and the limits before welding starts, because a weld outside the range cannot be corrected by rework.

What backing gas is used for duplex TIG root runs?

Pure nitrogen is what ESAB usually recommends, and N2 appears among the shielding options for its duplex TIG grades. Nitrogen is a strong austenite former and counts three times as heavily as molybdenum in the PRE calculation, so nitrogen lost from the root pool costs both austenite balance and pitting resistance. Substituting argon is a frequent and invisible site error.

What heat input and interpass temperature does duplex allow?

ESAB gives 5 to 25 kJ/cm for duplex — 0.5 to 2.5 kJ/mm — with a favourable cooling time of t12/8 = 8 to 10 seconds, and an interpass temperature not exceeding 250 °C. The 150 °C figure often quoted is the lean and super duplex limit, not the 2205 one. Too little heat input leaves excess ferrite; too much allows sigma phase to precipitate.

Is ER2209 stronger than ER316L?

Substantially. ER2209 deposits typically give 550 to 660 MPa yield against roughly 400 to 500 MPa for ER316L — about half as strong again — along with better chloride pitting resistance and resistance to chloride stress corrosion cracking, which austenitic grades are genuinely vulnerable to in warm chloride service.

Can ER2209 be used on super duplex?

No. Super duplex grades such as 2507 and UNS S32750 reach PRE 40 or above, and a 2209 deposit would have a lower PRE than the parent — making the weld the first thing to corrode in exactly the service the parent was specified to survive. Use ER2594 for super duplex.

Can duplex be TIG welded without filler?

It should generally be avoided. ESAB warns of the risk of cracking and insufficient microstructure formation, because an autogenous weld has no access to the extra nickel the filler supplies to form austenite during cooling. Where manual TIG is used, ensure a sufficient supply of filler into the pool.

Who supplies ER2209 duplex wire in Abu Dhabi?

POFIS supplies the ESAB OK Autrod and Exaton duplex ranges from Abu Dhabi across the UAE and the wider GCC, as an ESAB Authorized Distributor and Service Centre, approved ADNOC vendor and ISO 9001 certified supplier. Send the parent grade, the impact requirement and the ferrite acceptance range and we will confirm the wire against the procedure. Email weldiv@pofis.ae.

Procurement & supply

Buying the ER2209 consumables through POFIS

The ER2209 consumables is supplied from Abu Dhabi by Perfect Oilfield & Industrial Supply LLC as an ESAB Authorized Distributor and Service Centre. The information below covers what procurement and QA/QC departments normally need before raising a purchase order.

Lead time

Stock items dispatch from Abu Dhabi within 24–48 hours. Indent items are quoted with a confirmed lead time at the time of offer.

Approved vendor status

POFIS is an approved ADNOC vendor and is listed on the approved vendor lists (AVL) of major operators and EPC contractors across the GCC. We can complete supplier registration and prequalification documentation on request.

Payment terms

Standard credit terms are available to registered corporate accounts. LPO, LC and advance payment are all accepted.

Delivery terms

Delivery across the UAE and the wider GCC. Quotations can be issued on EXW, FOB, CIF or DDP terms to suit your project.

Warranty

Full manufacturer warranty, honoured locally. As an ESAB Authorized Service Centre we carry out warranty work and repairs in Abu Dhabi rather than returning equipment abroad.

Service & spares

In-UAE service, commissioning, operator training and spare parts backing for every machine we supply.

ISO 9001 Certified
Approved ADNOC Vendor
ESAB Authorized Distributor & Service Centre

Price on request

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