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Materials with high hardness are usually preferred in armour applications and are difficult to weld due to high Carbon Equivalent (C.E). In this investigation, an attempt was made to weld Ultra-high Hard Armour (UHA) steel (having C.E of 0.91) by Shielded Metal Arc Welding (SMAW) process using three electrodes (i) austenitic stainless steel (ASS- E307-16), (ii) super duplex stainless steel (SDSS-E2594-16) (iii) low hydrogen ferritic (LHF-E12018M-low-alloy steel electrode). The mechanical properties (tensile, impact toughness, and microhardness) were evaluated and correlated with microstructural features along with Cr eq /Ni eq ratio of weld metal. The joints fabricated using LHF electrodes showed superior strength of 962 MPa and hardness of 341 HV. The joints made using ASS electrode showed superior impact toughness of 72 J and Notch Strength Ratio (NSR) of 1.32 due to the higher energy absorption capability of the austenitic phase. At the weld interface, joints fabricated using ASS and SDSS electrodes show the unmixed zone (UMZ) and martensitic band (MB) due to sudden change of crystal structure (Face Centred Cubic (FCC) / Body Centred Tetragonal (BCT)). It is also found that the strength property increases (651 MPa to 856 MPa) with an increase in Cr eq /Ni eq ratio (1.87 to 3.2) of weld metal and with a decrease in ductility.

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