Postalloy® DuraForge™ 2235-FCG

Postalloy® DuraForge™ 2235-FCG is a flux-cored gas-shielded welding alloy that produces a tough impact resistant nickel-chromium-moly weld deposit. DuraForge™ 2235-FCG has good metal-to-metal wear properties at low and high temperatures. DuraForge™ 2235-FCG is commonly used in the forging industry for building up and repairing sow blocks, rams, die shanks, die holders or filling in complete impressions as required. DuraForge™ 2235-FCG has a self-releasing synthetic slag that allows it to be used at many different amperage/voltage settings. DuraForge™ 2235-FCG operates well at high amperage/voltage settings when high deposition rates are required. It also has a very stable arc and fast freezing slag when used at low amperage/volt settings.


Product Type

  • Flux-cored
  • Gas-shielded


  • Repair and build-up of hammer dies, rams, and sow blocks.
  • Also works well for joining hardenable steels such as 4140.

Weld Deposit Properties

Tensile Strength:
180,000 psi
34Rc - 40Rc

Welding Parameters

Current Type: DC Electrode Positive

Volts Amps Diameter Stick Out
25-29 200-300 1/16" (1.6mm) 1" (25mm)
26-32 250-450 3/32" (2.4mm) 1¼" (32mm)
32-40 400-700 1/8" (3.2mm) 1½" (38mm)

Welding Procedure:

Gas Cover Options (for all wire sizes):

75/25 Argon/CO2, 80/20 Argon/CO2, 90/10 Argon/CO2, 98/2 Argon/CO2.
Slow Cooling after welding is extremely important to reduce stress build-up and minimize the risk of cracking. Therefore, using this wire requires a minimum of preheat from 600-800 °F (315-427 °C) depending on size of the part and composition of the base metal. Throughout welding operation, limit interpass temperature to 900 °F (480 °C). After welding, the part should be returned to the preheat furnace to allow the temperature throughout the part to equalize.

Packaging Options

Diameter Standard Packaging
1/16" (1.6mm) 33 lb (15kgs) spool
3/32" (2.4mm) 55 lb (25kgs) coil
1/8" (3.2mm) 55 lb (25kgs) coil