high carbon steel to 309SL stainless

J & K,

My layman advice would be to use 309L. I have seen it in TIG and Stick, possibly even in MIG. I personally prefer TIG for the control it gives, but that's just me.

Regards, Jim

Me, personally? I'd use b - o - l - t - s ..

GWE

My preference it for aerospace alloys like Hastelloy W or Inconel 625 for joining dissimilar metals, but 309L is pretty good for this too.

Powder welding is ideal for this type of job, as well as for things like cast iron repairs. Sadly no one on this group seems to be familiar with the process, and I have little more than a good understanding of the basics.

Everything I have read concerning powder welding makes it look like another term for thermal spray coating or flame spraying. These aren't techniques used for sticking things together. Thermal spray coatings are usually porous as well.

Cheers,

Kelley

How True!

I wonder have you actually done any powder welding, or seen it being carried out?

It is known as a "Microfusion" process, and equipment and powder is manufactured by Eutectic.............it seems very strange that there seems to be such scant knowledge of this, as it works a great deal better than many other processes, especially for problematic repair jobs.