6) All unnotched and notched tensile specimens failed in the base metal, indicating a higher strength for the weld metal and HAZ than the base metal. 7) The Charpy impact toughness of weld metal, in general, is better than the base metal. The welds J2 and J3 with 5% and 10% CO2, respectively, exhibited relatively higher impact toughness values than the other weld metal. 8) Finally, as a whole, it can be concluded that up to 10% CO2 may be utilized in an Ar shielding gas mixture for fabricating welded joints of modified FSS (409M) using 308L filler metal in spray transfer mode without deteriorating microstructural or mechanical properties. Acknowledgments The authors would like to gratefully thank the Council of Scientific and Industrial Research (CSIR), Pusa, New Delhi, India, for funding this research with a senior research fellowship. The authors would also like to thank Dr. G. Das of National Metallurgical Laboratory, Jamshedpur, and Mrs. D. 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