Abstract Highlights of the present study is the importance of choosing suitable temperatures for two stage PWHT to achieve desirable toughness in the weld metals produced by ER 410NiMo filler wire. Weld pads prepared using this filler wire was used for extensive metallurgical characterization of the weld metal. Results indicate by choosing appropriate temperatures for the PWHT, it is possible to obtain toughness in the weld metal which is comparable to the toughness reported for the base metal of similar composition. Good toughness of the weld metal is attributed to the presence of retained austenite in the weld metal. Two stage PWHT that gave excellent toughness for the weld metal was employed for repair of cracked shrouds of a steam turbine in a nuclear power plant. The metallurgical characterization of the mock up weld pad prepared prior to actual repair confirmed that microstructure and hardness of the weld metal are similar to those obtained during the welding procedure development.