ERNiFeCr-1
1. Experience the exceptional performance of our nickel-based ERNiFeCr-1 welding wire, meticulously crafted within the Ni-Cr-Fe-Mo-Cu system. Specifically designed to thrive in corrosive and extreme thermal environments, this premium wire is your go-to solution for high-performance applications. Recognized under AWS classification A5.14 ERNiFeCr-1, this product also aligns perfectly with SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), ensuring global compatibility and superior quality.
Key Advantages:
Corrosion Resistance: Our welding rods excel in challenging reducing media, such as sulfuric and phosphoric acids. They effectively combat stress corrosion cracking, pitting, and crevice corrosion, ensuring long-lasting durability.
Thermal Stability: These rods maintain their mechanical integrity across a broad temperature range, from cryogenic conditions up to 900°C, making them an ideal choice for diverse applications.
Versatility: Perfectly suited for welding dissimilar metals, such as nickel alloys to steel, as well as cladding operations, offering unmatched flexibility in your welding projects.
2. Chemical Composition
ERNiFeCr-1's composition is meticulously optimized to ensure superior weld integrity, as illustrated in Table 1:
High Nickel (38-46%) and Iron (≥22%): These elements work in harmony to create a ductile matrix, balancing thermal expansion with strength for dependable performance.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components are key to enhancing oxidation resistance and ensuring stability in the presence of chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: These specifications are crucial in minimizing intergranular corrosion risks, safeguarding the longevity 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: Achieving a robust ≥550 MPa, this strength meets and exceeds the AWS A5.14 minimum requirements.
Elongation: With impressive ductility, these rods offer an elongation range of ~25-34%, ensuring resilience in demanding conditions.
Impact Toughness: Retains exceptional properties even in sub-zero environments, making it perfect for cryogenic storage tanks and similar applications.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: This standard mandates rigorous chemical and mechanical specifications to ensure top-tier performance.
ISO 18274: Embracing a global standardization with SNi8065 ensures consistent quality across international markets.
F-Number 45 (ASME IX): Qualifies welding procedures specifically for pressure vessels, affirming our product's reliability under pressure.
Quality Control: Each batch is accompanied by Material Test Certificates (MTC) and passes stringent RT/PT nondestructive testing, guaranteeing quality and reliability.
5. Applications
Primary Use: Expertly crafted for the welding of INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, offering strength and integrity.
Critical Industries:
Petrochemical: Ideal for reactors and acid-processing equipment, delivering robust performance under harsh conditions.
Nuclear: Perfect for steam generator tubes and pressure vessels, ensuring safety and reliability.
Aerospace: Essential for turbine components exposed to challenging thermal cycling, guaranteeing performance and longevity.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizing 100% argon shielding, this method is ideal for achieving precision joints, particularly in applications involving thin tubes. Experience unparalleled precision and quality in your welding projects with our specialized guidelines.
MIG (GMAW): Elevate your welding experience by achieving superior, deeper penetration in thicker sections with a precision-blended argon-helium mix at a 75%-25% ratio. This expertly crafted combination not only guarantees robust weld quality but also significantly enhances structural integrity, ensuring your projects stand the test of time.
Parameters Overview (Refer to Table 2 for detailed specifications): Delve into the comprehensive specifications outlined in Table 2 to fully understand the standardized welding parameters designed for optimal performance and precision.
Preheat/Cleaning: Achieving a flawless weld starts with meticulously eliminating all traces of oil and oxides. Employ either mechanical or chemical cleaning methods to ensure a spotless surface, setting the stage for optimal welding results and a pristine finish.
Interpass Temperature: Rigorously maintain a temperature of ≤150°C to prevent the detrimental formation of carbide precipitation, which can severely compromise the weld's integrity. This meticulous attention to detail ensures the longevity and reliability of your welds.
Table 2: Standardized Welding Parameters for Optimal Performance: Explore Table 2 to uncover the key parameters that drive unparalleled welding performance, crafted to meet the highest standards of precision and excellence.
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas: Discover the essential specifications across various processes, diameters, and shielding gases that optimize your welding operations.
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon for precise and controlled welding: Harness the precision and control of TIG welding with diameters of 0.9 to 3.2 mm, utilizing a current range of 60-220 (DCEN) and voltages between 12-20, all while benefiting from the purity of 100% Argon.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium for enhanced penetration and stability: Achieve enhanced penetration and stability in your MIG welding process with diameters of 0.9 to 1.6 mm, current settings from 150-250, and voltages of 26-33, complemented by a 75% Argon and 25% Helium shielding mix.
Source: The comprehensive source of all necessary information and guidelines to achieve superior welding results.
7. Procurement and Handling Guidelines: Ensure seamless integration and handling of materials by following essential procurement guidelines.
Packaging: Offered in convenient coils and spools ranging from 0.8 to 5.0 mm in diameter, designed for ease and efficiency; Available in convenient 10-25 kg units for easy handling and storage: Simplify your operations with units ranging from 10-25 kg, ensuring easy handling and optimal storage.
Storage: Preserve your welding materials in pristine condition by storing them in a dry environment where humidity levels stay below 60%, preventing any moisture absorption that could compromise weld quality.
8. Common Challenges & Their Effective Solutions: Navigate common welding challenges with confidence using our expertly curated solutions designed to maintain quality and performance.
Porosity: Often a result of gas impurities: Address porosity head-on, which is frequently caused by gas impurities, and ensure impeccable welds. → Ensure the use of high-purity argon (99.99%) to eliminate impurities and achieve flawless welds: Guarantee the integrity of your welds by using high-purity argon (99.99%), effectively eliminating impurities and ensuring flawless results.
Hot Cracking: Reduce the risk by employing low heat input and minimizing joint restraints to maintain weld integrity: Mitigate the risk of hot cracking by adopting strategies that involve a low heat input and minimizing joint restraints, thereby preserving the integrity and durability of your welds.
| 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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