ERNiFeCr-1
1. This advanced nickel-based welding wire, operating within the Ni-Cr-Fe-Mo-Cu system, is expertly crafted for high-performance use in corrosive and extreme thermal environments, setting a new standard for durability and effectiveness. This welding wire proudly aligns with AWS classification A5.14 ERNiFeCr-1, standing as a peer to SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), ensuring global compatibility and reliability.
Key Advantages:
Corrosion Resistance: Impressively withstands reducing media such as sulfuric and phosphoric acids, while offering strong resistance against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Reliably maintains its mechanical integrity across a wide temperature spectrum from cryogenic levels up to 900°C, ensuring consistent performance.
Versatility: Perfectly suited for welding dissimilar metals, such as nickel alloys to steel, and excelling in cladding operations, offering unmatched flexibility.
2. Chemical Composition
The composition of ERNiFeCr-1 (refer to Table 1) is meticulously optimized to enhance weld integrity, ensuring superior performance.
High Nickel (38-46%) and Iron (≥22%): These elements create a ductile matrix, providing an ideal balance of thermal expansion and strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components significantly boost oxidation resistance and stability, particularly in corrosive environments like chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: This minimizes the risks of intergranular corrosion, ensuring long-lasting durability.
Table 1: Chemical Composition (Weight %)
Element Ni Fe Cr Mo Cu Mn Si Others
Range 38-46% ≥22% 19.5-23.5% 2.5-3.5% 1.5-3.0% ≤1% ≤0.5% Ti: 0.6-1.2%; Al≤0.2%
Source: 3. Mechanical Properties
As-Welded Performance:
Tensile Strength: Achieves a robust ≥550 MPa, meeting AWS A5.14's stringent minimum requirements effortlessly.
Elongation: Exhibits outstanding ductility with an elongation range of approximately 25-34%.
Impact Toughness: Remarkably retains its properties even in sub-zero environments, such as those found in cryogenic storage tanks, demonstrating exceptional resilience.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate rigorous chemical and mechanical specifications, ensuring top-tier quality.
ISO 18274: Establishes global standardization (SNi8065), confirming international acceptance and compliance.
F-Number 45 (ASME IX): This number qualifies welding procedures specifically for pressure vessels, guaranteeing safety and reliability.
Quality Control: Demands Material Test Certificates (MTC) and necessitates passing stringent RT/PT nondestructive testing, ensuring the highest quality assurance.
5. Applications
Primary Use: Specially formulated for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, ensuring seamless integration and performance.
Critical Industries:
Petrochemical: Ideal for reactors and acid-processing equipment, where reliability and performance are critical.
Nuclear: Essential for the integrity of steam generator tubes and pressure vessels, supporting safety and efficiency.
Aerospace: Perfect for turbine components that endure thermal cycling, ensuring lasting durability and performance.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it ideal for precision joints, such as those in thin tubes, offering unmatched precision and quality. ideal for precision joints (e.g., thin tubes) .
MIG (GMAW): For welds requiring superior structural strength and deeper penetration in thicker metal sections, utilize an argon-helium blend at a 75%-25% ratio. This carefully crafted combination not only guarantees robust weld quality but also significantly enhances the overall structural integrity.
Parameters Overview: For detailed specifications that ensure optimal performance and precision, please refer to Table 2.
Preheat/Cleaning: It's absolutely vital to meticulously remove any traces of oil and oxides. This can be achieved through mechanical or chemical cleaning methods. This crucial step guarantees a spotless surface, ensuring optimal welding results and superior weld quality.
Interpass Temperature: Maintain an exact temperature of ≤150°C to meticulously prevent carbide precipitation. This precision is essential to ensure the weld's integrity is not compromised.
Table 2: Standardized Welding Parameters for Achieving Optimal Performance
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG Welding: Utilize diameters from 0.9-3.2 mm with a current of 60-220 (DCEN) and a voltage range of 12-20. Employ 100% Argon for achieving precise and controlled welding outcomes.
MIG Welding: For enhanced penetration and stability, use diameters from 0.9-1.6 mm, with a current of 150-250 and voltage settings of 26-33. Opt for a shielding gas blend of 75% Argon and 25% Helium.
Source:
7. Procurement and Handling Guidelines: Follow these practices for optimal handling and procurement of the welding rods.
Packaging: Available in versatile coils and spools, with diameters ranging from 0.8 to 5.0 mm, suiting diverse welding needs. Available in user-friendly 10-25 kg units, these packaging sizes ensure easy handling, convenient storage, and efficient workflow management.
Storage: For maintaining premium weld quality, store the rods in a dry setting where humidity levels remain below 60%, preventing moisture absorption.
8. Common Challenges & Their Effective Solutions: Navigate welding challenges with confidence using these solutions.
Porosity: Typically caused by gas impurities, this common issue can be effectively managed. → Ensure the use of high-purity argon (99.99%) for welding to completely eliminate impurities, resulting in flawless, pristine welds.
Hot Cracking: Mitigate this risk by employing low heat input techniques and minimizing joint restraints, thus maintaining superior weld integrity.
| AWS A5.4 |
ERNi-1 |
ERNiCu-7 |
ERNiCr-3 |
ERNiCrFe-5 |
ERNiCrMo-3 |
ERNiCrMo-4 |
ERNiCrMo-7 |
| TS(N/mm2) |
460 |
541 |
671 |
560 |
790 |
729 |
780 |
| EL(%) |
30 |
39 |
39 |
30 |
43 |
33 |
35 |
| C |
0.02 |
0.02 |
0.03 |
0.03 |
0.0037 |
0.002 |
0.05 |
| Mn |
0.3 |
1.7 |
3.05 |
1 |
0.03 |
0.12 |
0.6 |
| Si |
0.16 |
0.44 |
0.37 |
0.04 |
0.029 |
0.07 |
0.02 |
| P |
0.0012 |
0.007 |
/ |
0.004 |
0.003 |
0.003 |
0.003 |
| Ti |
2.3 |
/ |
0.01 |
/ |
0.088 |
/ |
/ |
| S |
0.005 |
0.008 |
/ |
0.002 |
0.001 |
0.0015 |
|
| Cr |
/ |
/ |
19.86 |
15.7 |
21.95 |
15.9 |
16.7 |
| Ni |
96.5 |
65.68 |
72.8 |
75.06 |
64.65 |
REM |
REM |
| Cu |
/ |
REM |
0.06 |
0.03 |
0.009 |
0.008 |
/ |
| Mo |
/ |
/ |
/ |
0.03 |
9.04 |
15.9 |
15.8 |
| Nb |
/ |
/ |
2.4 |
2.3 |
3.61 |
/ |
/ |
| V |
/ |
/ |
/ |
/ |
/ |
0.01 |
/ |
| Fe |
/ |
0.7 |
0.23 |
7.9 |
0.19 |
4.12 |
2.2 |
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