Inconel welds are prone to cracking, which makes welding quite tricky. Therefore, some Inconel alloys are specifically designed for welding. For example, Inconel 625 is very easy to weld compared to other Inconel alloys. Inconel 718 is another alloy that is particularly weldable. Its high iron content makes it less expensive per kilogram than other materials of the same type, and it is precipitation hardened, reducing the likelihood of cracking.

Electron beam welding is generally considered the preferred welding process for high-temperature alloys such as Inconel. Electron beam welding has the high power required to melt materials quickly, ensuring a very narrow fusion zone (FZ) and a minimized heat-affected zone (HAZ), thereby reducing distortion and residual stresses. Electron beam welding is performed in a vacuum, which reduces material contamination and produces clean welds at any depth of penetration.

There are two main methods for passivating Inconel, and the method is very similar to that of 300 series stainless steel. One option is to immerse Inconel parts in a 25-50% nitric acid solution at room temperature to about 140 degree F (60 degree ) for about 20-30 minutes. A similar soaking process can be performed using a 10% citric acid solution at a similar temperature range and time.