Calculating TIG filler rod?

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I am planning to put down 200ft of weldment. I am welding 1/4" plate to 14gauge sheet. 100 ft of weld will be CORTEN (weathering steel) to COR-TEN, and 100' of weld will be 1/4" 304 stainless steel to COR-TEN. I will be TIG welding all of these seams. I am planning to use 3/32" 309 stainless fill rod for the stainless to COR-TEN weld. What fill material should I use for the COR-TEN to COR-TEN weld? Is there a specific filler rod alloy to use with weathering steel or am I fine to just use a basic mild steel fill rod. AND, is there a calculator or formula that I can use to determine how much fill rod I will need? Thank You for any suggestions!
Reply:For filler volume, if you made a 3/16" x 3/16" flat faced weld 2400" long:(1/2)(3/16)(3/16)(2400) = 42.2 cubic inches.Stainless 300 series = 0.29 lbs/cu. inch42.2 x 0.29 = 12.2 lbs of rod.This is purely theoretical of course and is based on a presumed leg length and filler metal density.Note: leg length makes a big difference. 1/8" legs brings the weight down to 5.4 lbs.Last edited by MinnesotaDave; 06-19-2014 at 05:43 PM.Dave J.Beware of false knowledge; it is more dangerous than ignorance. ~George Bernard Shaw~ Syncro 350Invertec v250-sThermal Arc 161 and 300MM210DialarcTried being normal once, didn't take....I think it was a Tuesday.
Reply:http://www.metrode.com/en-gb/alloy-f...80s-w-tig.htmlDon't be afraid to use Google.    Who knows if that's really what's needed though.  I just use google.   1st on WeldingWeb to have a scrolling sig! HTP Invertig 400HTP Invertig 221HTP ProPulse 300HTP ProPulse 200 x2HTP ProPulse 220MTSHTP Inverarc 200TLP HTP Microcut 875SC
Reply:ER80S-Ni1 is the most common filler for weathering steel. I have heard that filler metals with the "W" classification are falling out of favor because too high a concentration of alloying elements can cause cracking and lower ductility. Probably not a major issue for a sculpture though.   Some people use plain mild steel filler (S-2 or S-6) for small welds but for a large job I would advise against it.JohnA few weldersA lot of hammersA whole lot of C-clamps