ERNiFeCr-1
1. Introducing our premium nickel-based welding wire, expertly crafted in the Ni-Cr-Fe-Mo-Cu system. Designed to meet the highest standards of performance, it thrives in corrosive and extreme thermal environments, ensuring durability and reliability. Proudly classified under the esteemed AWS A5.14 ERNiFeCr-1, this product also holds equivalence with SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), showcasing its global recognition and versatility.
Key Advantages:
Corrosion Resistance: This standout product excels in reducing media such as sulfuric and phosphoric acids, and offers robust protection against stress corrosion cracking, as well as pitting and crevice corrosion.
Thermal Stability: It ensures mechanical integrity from the harshest cryogenic temperatures up to a remarkable 900°C, making it ideal for a wide range of extreme applications.
Versatility: Perfect for welding dissimilar metals, including nickel alloys to steel, and is exceedingly suitable for cladding operations, making it an indispensable tool in your welding arsenal.
2. Chemical Composition
ERNiFeCr-1's composition is ingeniously optimized for superior weld integrity, as detailed in Table 1: Chemical Composition.
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix that skillfully balances thermal expansion with strength, ensuring excellent performance.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components significantly enhance the wire's oxidation resistance and stability, particularly in challenging chlorides and sulfides environments.
Low Carbon (≤0.05%) and Impurities: A thoughtful composition that minimizes the risks of intergranular corrosion, securing the integrity and longevity of your projects.
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, comfortably meeting and exceeding the AWS A5.14 minimum requirements.
Elongation: Boasts an impressive range of ~25-34%, offering exceptional ductility and flexibility.
Impact Toughness: Maintains its exceptional properties even in sub-zero temperatures, perfect for applications such as cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate stringent chemical and mechanical specifications, ensuring top-notch quality.
ISO 18274: Recognized globally under the standardization of SNi8065, reinforcing its international reliability.
F-Number 45 (ASME IX): This classification qualifies it for welding procedures on pressure vessels, marking its excellence in critical applications.
Quality Control: Adopts rigorous quality measures requiring Material Test Certificates (MTC) and conforms to RT/PT nondestructive testing standards, ensuring unmatched reliability.
5. Applications
Primary Use: Specifically designed for welding INCOLOY 825 (UNS N08825) and compatible Ni-Fe-Cr-Mo-Cu alloys, offering unmatched compatibility and performance.
Critical Industries:
Petrochemical: Perfectly suited for reactors and acid-processing equipment, providing outstanding durability and resistance.
Nuclear: Ideal for steam generator tubes and pressure vessels, meeting the high demands of the nuclear industry.
Aerospace: Essential for turbine components that endure thermal cycling, ensuring safety and reliability in flight.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it the ideal choice for precision joints, such as those required in thin tubes. Offering unparalleled precision, it's perfect for delicate applications demanding meticulous attention to detail.
MIG (GMAW): Unleash superior welding potential with a 75%-25% argon-helium blend, delivering deeper penetration in thicker sections. This winning combination not only guarantees robust weld quality but also significantly enhances the structural integrity of your projects.
Parameters Overview: Dive into the specifics with Table 2, which offers a comprehensive breakdown of detailed specifications tailored for precision and excellence.
Preheat/Cleaning: Achieve immaculate welding surfaces by rigorously removing oil and oxides through advanced mechanical or chemical cleaning methods. This critical step ensures a pristine surface, paving the way for the best welding outcomes.
Interpass Temperature: Diligently maintain temperatures at or below 150°C to effectively prevent carbide precipitation, thereby safeguarding the weld's integrity and ensuring long-lasting durability.
Table 2: Standardized Welding Parameters for Peak Performance
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2 60-220 (DCEN) 12-20 Utilize 100% Argon for welding precision and exceptional control.
MIG 0.9-1.6 150-250 26-33 Employ 75% Argon + 25% Helium to achieve enhanced penetration and unparalleled stability.
Source:
7. Procurement and Handling Guidelines
Packaging: Choose from coils and spools available in diameters ranging from 0.8 to 5.0 mm, designed for adaptability and efficiency. Conveniently packaged in 10-25 kg units, ensuring ease of handling and optimal storage solutions.
Storage: Maintain a dry storage environment with humidity levels below 60% to prevent moisture absorption, which could compromise weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Often a result of gas impurities → Ensure the use of ultra-pure argon (99.99%) to meticulously eliminate impurities, achieving immaculate and flawless welds.
Hot Cracking: Skillfully minimize risks by adopting low heat input techniques and reducing joint restraints, all while maintaining uncompromised 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 |
