Inconel 617 Filler Metal and Incoloy 800HT: Top Filler Metals for High-Temperature Applications

As industries continue to push the boundaries of high-temperature applications, the need for reliable and durable filler metals becomes more crucial. Inconel 617 filler metal and Incoloy 800HT are two of the most sought-after filler metals in the market, offering unparalleled performance and resistance to oxidation, corrosion, and various high-temperature challenges. In this blog post, we will delve into the unique properties, pros, cons, and applications of these top-notch filler metals, guiding you in your quest to find the perfect solution for your high-temperature welding needs.

Overview of Premium High-Temperature Filler Metals

Premium high-temperature filler metals, including Inconel 617 and Incoloy 800HT, are specifically designed to offer remarkable strength, corrosion resistance, and thermal stability in extreme heat conditions, usually above 1000°F (538°C). These properties are essential for industries such as aerospace, power generation, petrochemical, and furnace manufacturing, where components often need to withstand high temperatures and harsh environments. With high nickel content and suitable material properties, filler metals like aws a5.14 ernicrcomo 1 have been developed to cater to these demanding applications.

Inconel 617, a nickel-chromium-cobalt-molybdenum alloy, was developed in the 1970s and is recognized for its excellent oxidation and corrosion resistance, as well as exceptional creep strength at elevated temperatures. On the other hand, Incoloy 800HT, developed before December 1932, has high-temperature strength and oxidation resistance, making it an ideal choice for components that require high-temperature performance. Both alloys are suitable for land-based gas turbines and other high-temperature applications due to their attractive material properties and readily formed nature.

When it comes to the welding of inconel alloy, specifically Inconel 617, the choice of filler metal is crucial for achieving optimal results. Gas tungsten arc and gas metal arc welding techniques, as conventional techniques, are often employed with Inconel 617 and Incoloy 800HT filler metals, providing excellent resistance to oxidation, corrosion, and high-temperature strength.

The subsequent sections will delve into the distinct advantages and disadvantages of these high-performing filler metals, such components being accompanied by personal reviews to guide your decision-making process.

INCONEL Filler Metal 617: The Best Choice for Welding High-Temperature Alloys

INCONEL Filler Metal 617 is a top choice for welding high-temperature alloys like INCONEL alloy 617, INCOLOY alloys 800HT and 803, and cast alloys such as HK-40, HP, and HP-45 Modified. Its use in gas-tungsten-arc and gas-metal-arc welding processes ensures compatibility with these alloys and delivers exceptional performance in challenging environments.

Pros of INCONEL Filler Metal 617

One of the significant advantages of INCONEL Filler Metal 617 is its resistance to a wide range of corrosive environments. Its high temperature strength, oxidation resistance, and metallurgical stability contribute to its effective performance in demanding applications.

INCONEL Filler Metal 617 is composed of a substantial amount of nickel, chromium, and aluminum, providing a solid-solution alloy that boasts high-temperature strength and oxidation resistance.

In addition to its resistance to corrosion, INCONEL Filler Metal 617 also offers superior mechanical properties across a wide range of temperatures. Its density is 8.36 g/cm3, and its melting range is 1363°C to 2485°F, making it an attractive material for high-temperature applications due to its corrosion resistance and strength. Furthermore, it can be readily formed and welded using standard techniques for nickel alloys, ensuring compatibility with various high-temperature alloys and applications.

Cons of INCONEL Filler Metal 617

Despite its outstanding performance in high-temperature applications, INCONEL Filler Metal 617 does have some drawbacks, primarily related to its cost and accessibility. Although it is readily available from various suppliers and manufacturers, the price of INCONEL Filler Metal 617 may be higher than other high-temperature filler metals. Considering your budget and project requirements is a vital step in selecting the most suitable filler metal.

Another potential issue when welding with INCONEL Filler Metal 617 is the possibility of solidification cracking, poor corrosion resistance, and macrosegregation. These complications may arise depending on the alloy and service conditions, Therefore, it’s important to familiarize yourself with these potential challenges and implement suitable precautions during welding.

Personal Review of INCONEL Filler Metal 617

As a frequent user of INCONEL Filler Metal 617, I find its superior qualities to be invaluable in various high-temperature applications. Here are some of its key features:

  • Superior weldability
  • Excellent heat resistance
  • Compatibility with gas-tungsten-arc and gas-metal-arc welding processes
  • Reliable bond with INCONEL alloy 617 and other dissimilar high-temperature alloys
  • Exceptional bonding strength
  • Marginally higher tensile strength compared to other weld joints

These qualities make INCONEL Filler Metal 617 a reliable choice for demanding projects.

In my experience, INCONEL Filler Metal 617 has consistently performed well in high-temperature environments, maintaining its strength and oxidation resistance at temperatures above 1800°F.

While some users might find the cost and potential welding complications concerning, the robust performance and durability of INCONEL Filler Metal 617 justify its investment value for those in search of a superior filler metal for high-temperature applications.

INCOLOY alloys 800HT: The Ultimate Filler Metal for Creep Rupture Strength

INCOLOY alloys 800HT is an iron-nickel-chromium alloy with superior creep rupture strength and high-temperature properties, making it an ideal filler metal for various applications.

Its exceptional resistance to carburization, oxidation, and nitriding atmospheres ensures reliable performance in even the most demanding high-temperature environments.

Pros of INCOLOY alloys 800HT

INCOLOY alloys 800HT offers numerous benefits, including:

  • Outstanding resistance to carburization, oxidation, and nitriding atmospheres
  • Superior protection against high-temperature corrosion
  • Preservation of mechanical properties and performance of the alloy
  • Exceptional resistance to corrosion
  • Ability to withstand atmospheres that alternate between reducing and oxidizing

Another significant advantage of INCOLOY alloys 800HT is its remarkable creep rupture strength. The alloy can endure prolonged exposure to high temperatures without deformation or failure, making it an excellent choice for high-temperature applications. The precise control of carbon, aluminum, and titanium contents in INCOLOY alloys 800HT contributes to its higher strength, further enhancing its performance in high-temperature environments.

Cons of INCOLOY alloys 800HT

The primary drawbacks associated with the utilization of INCOLOY alloys 800HT are cost and accessibility. Although this alloy is more economical than other high-temperature filler metals, When choosing the right filler metal, it’s important to bear in mind your budget and project requirements.

While INCOLOY alloys 800HT are readily accessible from various suppliers and manufacturers, there are no reported material weaknesses for INCOLOY alloy 800HT. However, it is crucial to be aware of potential issues that may arise with other filler metals, such as segregation in the unmixed zone, depending on the alloy and service conditions.

Personal Review of INCOLOY alloys 800HT

I have found INCOLOY alloys 800HT to be an exceptional choice for high-temperature applications, offering unparalleled resistance to carburization, oxidation, and sulfidation. In addition to its outstanding performance and durability, INCOLOY alloys 800HT provides excellent cold-forming characteristics and can be welded using common techniques used on stainless steels.

In my experience, INCOLOY alloys 800HT has consistently performed well in various applications, such as:

  • Ethylene pyrolysis
  • Hydrocarbon cracking
  • Cracking furnaces
  • Heat exchangers
  • Process piping
  • Furnace components
  • Electric range heating element sheathing
  • Ammonia effluent coolers
  • Heat treating equipment
  • Chemical processing

Its resistance to embrittlement allows the alloy to maintain its structural integrity and mechanical properties, ensuring long-term durability in high-temperature applications.

Choosing the Right Filler Metal for Your High-Temperature Applications

A range of factors need to be taken into account when choosing the right filler metal for your high-temperature applications, including:

  • Base material compatibility
  • Cracking sensitivity
  • Strength
  • Ductility
  • Corrosion resistance
  • Elevated-temperature service
  • Post-weld heat treatment requirements

Furthermore, don’t forget to weigh the cost and availability of the filler metal when making your decision.

Inconel 617 and Incoloy 800HT are two prime choices for high-temperature filler metals, offering exceptional performance and resistance to harsh environments. Both filler metals are available in various product forms and diameters, making them suitable for a wide range of high-temperature welding applications.

Your final choice between Inconel 617 and Incoloy 800HT will be influenced by your specific application requirements, budget, and the properties of the material. By weighing the factors discussed above and assessing the advantages and disadvantages of each filler metal, you’ll be equipped to make an informed decision and choose the most suitable filler metal for your high-temperature welding tasks.


In conclusion, Inconel 617 and Incoloy 800HT are top-performing filler metals that offer exceptional performance and durability in high-temperature applications. With their unique properties, such as high-temperature strength, oxidation resistance, and corrosion resistance, these filler metals are well-suited for industries such as aerospace, power generation, petrochemical, and furnace manufacturing. By carefully considering factors such as material properties, cost, and availability, you can choose the right filler metal that meets your high-temperature welding requirements and ensures long-lasting performance.

Frequently Asked Questions

What is the filler metal for INCONEL?

INCONEL Filler Metal 625 is used for gas-metal-arc and gas-tungsten-arc welding of INCONEL alloy 625, INCOLOY alloy 825, INCOLOY alloy 25-6MO, and a range of high alloy austenitic and super austenitic stainless steels.

What is Inco 617 filler?

Inco 617 filler is a nickel-chromium-based superalloy used for gas-tungsten-arc and gas-metal-arc welding of INCONEL alloy 617. It is known for its high temperature strength, oxidation resistance and metallurgical stability, making it suitable for joining various dissimilar high-temperature alloys. This alloy is ideal for applications that require high temperature strength and oxidation resistance, such as aerospace components, turbine blades, and exhaust systems. It is also used in the fabrication of nuclear reactors and other nuclear components. In addition, it is used in the production of high-temperature furnace components

What is INCONEL 617 used for?

INCONEL 617 is commonly used in the production of nitric acid, for heat-treating baskets and reduction boats in the refining of molybdenum due to its resistance to high-temperature corrosion.

What is the composition of INCONEL 617?

INCONEL® 617 is a solid-solution, strengthened alloy of nickel, chromium, cobalt and molybdenum that offers an exceptional combination of high-temperature strength and oxidation resistance.

What are the primary applications of Inconel 617 and Incoloy 800HT filler metals?

Inconel 617 and Incoloy 800HT filler metals are primarily used in applications which require components to withstand high temperatures and harsh environments, such as aerospace, power generation, petrochemical, and furnace manufacturing.

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