ERNiFeCr-1
1. Introducing a top-tier nickel-based welding wire, the ERNiFeCr-1. This remarkable wire (Ni-Cr-Fe-Mo-Cu system) is meticulously engineered for superior performance in challenging corrosive and extreme thermal environments, assuring reliability and excellence. This exceptional welding wire is categorized under the AWS classification A5.14 ERNiFeCr-1 and is also recognized as SNi8065 (ISO 18274) and NiFe30Cr21Mo3 according to the European standard.
Key Advantages:
Corrosion Resistance: Experience outstanding performance in reducing media such as sulfuric and phosphoric acids. The wire is expertly designed to resist stress corrosion cracking, pitting, and crevice corrosion, ensuring durability and longevity.
Thermal Stability: The wire maintains its mechanical integrity across a wide temperature range, from cryogenic levels up to an impressive 900°C, providing unmatched stability.
Versatility: Perfectly suited for welding dissimilar metals, such as joining nickel alloys to steel, and for cladding operations, offering flexibility in various industrial applications.
2. Chemical Composition
The composition of ERNiFeCr-1 (detailed in Table 1) is finely tuned for optimal weld integrity, ensuring outstanding performance.
High Nickel (38-46%) and Iron (≥22%): These elements create a robust, ductile matrix that strikes a perfect balance between thermal expansion and strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components significantly enhance oxidation resistance and ensure stability in environments containing chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: Designed to minimize the risk of intergranular corrosion, safeguarding the integrity of your welds.
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: The wire boasts a tensile strength of ≥550 MPa, meeting and exceeding AWS A5.14 minimum requirements.
Elongation: Exhibits an impressive elongation range of ~25-34%, demonstrating excellent ductility and flexibility.
Impact Toughness: Remarkably retains its properties even in sub-zero environments, making it ideal for applications such as cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate the stringent chemical and mechanical specifications, ensuring top-notch quality.
ISO 18274: This certification provides global standardization under the designation SNi8065.
F-Number 45 (ASME IX): Authorizes welding procedures for pressure vessels, ensuring compliance and safety.
Quality Control: Demands Material Test Certificates (MTC) and successfully passes rigorous RT/PT nondestructive testing, attesting to its precision and reliability.
5. Applications
Primary Use: Expertly crafted for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, this wire is essential for high-performance tasks.
Critical Industries:
Petrochemical: Perfect for reactors and acid-processing equipment, delivering dependable results.
Nuclear: Ideal for steam generator tubes and pressure vessels, ensuring robustness and safety.
Aerospace: Essential for turbine components exposed to thermal cycling, providing reliability under extreme conditions.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilize 100% argon shielding for optimal results; particularly effective for precision joints, such as those found in thin tubes, ensuring a flawless finish.
MIG (GMAW): Achieve unparalleled penetration depth in thicker sections by utilizing an argon-helium blend mixed at an optimal 75%-25% ratio. This carefully selected combination not only assures exceptional weld quality but also significantly enhances the structural integrity of your workpiece.
Parameters Overview (Refer to Table 2 for detailed specifications):
Preheat/Cleaning: The elimination of any oil and oxides is an imperative step. Employ either mechanical or chemical cleaning methods to ensure a flawlessly clean surface, setting the stage for achieving premium welding results.
Interpass Temperature: Carefully maintain a precise temperature of ≤150°C. This meticulous control is essential to prevent unwanted carbide precipitation, which could otherwise compromise the structural integrity of the weld.
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 achieving precise and controlled welding outcomes.
MIG 0.9-1.6 150-250 26-33 A blend of 75% Argon + 25% Helium for superior penetration and unmatched stability in your welds.
Source:
7. Procurement and Handling Guidelines
Packaging: Offered in both coils and spools, available in a comprehensive range of diameters from 0.8 to 5.0 mm, catering to various welding needs; Conveniently packaged in units ranging from 10 to 25 kg, designed for ease of handling and storage efficiency.
Storage: Optimal storage requires a dry environment with humidity strictly below 60% to prevent any moisture absorption that could degrade weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Commonly caused by gas impurities → Ensure the exclusive use of high-purity argon (99.99%) to effectively eliminate impurities and achieve flawless welds with utmost precision.
Hot Cracking: Mitigate this risk by ensuring low heat input and minimizing joint restraints, crucial steps for maintaining the weld's integrity and strength.
| 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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