Well this is an interesting one....we've been asked to put a stand together for a customer to use at the upcoming offshore Europe exhibition. It involves welding some thick (~1" wall section) caps made from (what we're pretty sure is) 4140 quenched and tempered 80ksi to some very thin (2mm thick) S355 plate. It's basically a pipe to plate fillet weld where the pipe is going to be horizontal and have around 100kg hanging off it. We've welded 4140 before and have a WPS for it, but we can't really run it here because it'll be impossible to PWHT the joint. The stand doesn't need to be leak proof - just needs to support ~ 100kg of weight attached to these caps so there will be a bending moment on the weld. My question is - knowing how crack susceptible it will be to do this with ER80 (even if we pre-heat it), could we stick these together using a 309 or 312 wire to make a more reliable weld? The ultimate strength really isn't an issue but embrittlement and cracking could be.....Thoughts on a postcard please!