ERNiFeCr-1
1. Introducing a premium nickel-based welding wire, ERNiFeCr-1, crafted for excellence in highly demanding environments! It belongs to the exemplary Ni-Cr-Fe-Mo-Cu system, ensuring unparalleled performance where corrosion and extreme temperatures prevail. Belonging to the AWS A5.14 ERNiFeCr-1 category, this remarkable wire is also recognized as SNi8065 in ISO 18274 and aligns with the European NiFe30Cr21Mo3 standards.
Key Advantages:
Corrosion Resistance: Exceptional performance against reducing media such as sulfuric and phosphoric acids, effectively combating stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Delivers steadfast mechanical integrity from the depths of cryogenic temperatures soaring up to an impressive 900°C.
Versatility: An ideal choice for welding dissimilar metals, notably nickel alloys to steel, and excels in cladding operations.
2. Chemical Composition
ERNiFeCr-1 is meticulously crafted with a composition designed for optimal weld integrity, detailed in Table 1:
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix, skillfully balancing thermal expansion with strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): Enhance oxidation resistance, ensuring stability even in environments high in chlorides and sulfides.
Low Carbon (≤0.05%) and Minimal Impurities: A strategic composition to minimize risks of intergranular corrosion.
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: Stands robust at ≥550 MPa, meeting the rigorous demands of AWS A5.14 standards.
Elongation: Offers impressive elongation ranging between ~25-34%, showcasing excellent ductility.
Impact Toughness: Maintains superior properties even in sub-zero environments, perfect for applications such as cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Adheres to strict chemical and mechanical specifications.
ISO 18274: Represents global standardization under SNi8065.
F-Number 45 (ASME IX): Qualifies critical welding procedures for pressure vessels.
Quality Control: Includes Material Test Certificates (MTC) and secures approval through RT/PT nondestructive testing methods.
5. Applications
Primary Use: Expertly suited for welding INCOLOY 825 (UNS N08825) and akin Ni-Fe-Cr-Mo-Cu alloys.
Critical Industries:
Petrochemical: Vital for reactors and acid-processing equipment.
Nuclear: Integral for steam generator tubes and pressure vessels.
Aerospace: Essential for turbine components subjected to thermal cycling.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, ideal for achieving precision in joints, especially in thin tubes. Perfectly suited for creating precision joints, such as in thin tube applications.
MIG (GMAW): For achieving unparalleled weld quality with deeper penetration in thicker sections, utilize an argon-helium blend in a precise 75%-25% ratio. This powerful combination guarantees robust weld integrity and superior structural performance.
Parameters Overview (Consult Table 2 for comprehensive specifications):
Preheat/Cleaning: It is of utmost importance to meticulously eliminate any traces of oil and oxides using either mechanical or chemical cleaning techniques. This vital step ensures an immaculate surface, paving the way for exceptional welding results.
Interpass Temperature: Diligently maintain a temperature of ≤150°C to expertly prevent carbide precipitation, thus safeguarding the weld's structural integrity and quality.
Table 2: Standardized Welding Parameters for Optimal Performance
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2 60-220 (DCEN) 12-20 Utilize 100% Argon for precise, controlled, and refined welding operations.
MIG 0.9-1.6 150-250 26-33 Employ a 75% Argon + 25% Helium mix to ensure enhanced penetration and stability in welding processes.
Source:
7. Procurement and Handling Guidelines
Packaging: Available in versatile coils and spools with diameters ranging from 0.8 to 5.0 mm, meeting diverse welding needs; Available in user-friendly 10-25 kg units designed for effortless handling and convenient storage.
Storage: Store in a dry environment with humidity levels below 60% to effectively prevent moisture absorption, preserving superior weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Frequently caused by gas impurities → Ensure the use of ultra-high-purity argon (99.99%) to eradicate impurities, achieving immaculate welds with flawless quality.
Hot Cracking: Mitigate the risk by strategically using low heat input and minimizing joint restraints to uphold 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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