ERNiFeCr-1
1. This exceptional nickel-based welding wire, part of the Ni-Cr-Fe-Mo-Cu system, is meticulously engineered for high-performance applications. It shines brilliantly in environments that are both corrosive and subjected to extreme thermal conditions. It proudly holds the AWS classification A5.14 ERNiFeCr-1 and is also recognized as SNi8065 in ISO 18274, and NiFe30Cr21Mo3 according to the European standard, ensuring its global compatibility and excellence.
Key Advantages:
Corrosion Resistance: This wire is masterful in resisting reducing media like sulfuric and phosphoric acids. It also provides robust defense against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: It maintains its mechanical integrity from temperatures as low as cryogenic levels to a remarkable 900°C, ensuring reliability under varied thermal conditions.
Versatility: Perfectly suited for welding dissimilar metals such as nickel alloys to steel, as well as for sophisticated cladding operations.
2. Chemical Composition
ERNiFeCr-1's carefully crafted composition, detailed in Table 1, is optimized to ensure impeccable weld integrity and performance:
High Nickel (38-46%) and Iron (≥22%): These elements create a ductile matrix that adeptly balances thermal expansion with remarkable strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): They significantly enhance oxidation resistance and ensure stability in environments containing chlorides or sulfides.
Low Carbon (≤0.05%) and minimized impurities: This precise formulation reduces the risk of intergranular corrosion, ensuring long-lasting 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: With a minimum of 550 MPa, it meets and surpasses the AWS A5.14 standards, ensuring strong and reliable welds.
Elongation: Approximately 25-34%, showcasing its excellent ductility and adaptability in various applications.
Impact Toughness: Remarkably retains its properties even in sub-zero environments, making it ideal for use in cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards meticulously mandate the chemical and mechanical specifications.
ISO 18274: This ensures global standardization with the SNi8065 designation.
F-Number 45 (ASME IX): This qualifies welding procedures specifically for pressure vessels, ensuring utmost safety and reliability.
Quality Control: Rigorous protocols demand Material Test Certificates (MTC) and successful completion of RT/PT nondestructive testing for assured quality.
5. Applications
Primary Use: Expertly designed for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, ensuring durable and high-quality joins.
Critical Industries:
Petrochemical: Ideal for reactors and acid-processing equipment, where resilience is paramount.
Nuclear: Essential for steam generator tubes and pressure vessels, offering unmatched safety and performance.
Aerospace: Perfect for turbine components that are regularly exposed to demanding thermal cycling.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it ideal for achieving precision joints, especially in applications like thin tube welding. Ideal for precision joints, such as those required in thin tube welding, ensuring perfection in every application.
MIG (GMAW): Achieve unparalleled, deeper penetration in thicker sections by utilizing an expertly crafted argon-helium blend in a 75%-25% ratio. This sophisticated combination guarantees exceptional weld quality and significantly bolsters structural integrity, ensuring your projects stand the test of time.
Parameters Overview: For a comprehensive understanding of the specifications, please refer to Table 2, where every detail is meticulously laid out for your convenience.
Preheat/Cleaning: To achieve a truly pristine surface, it is vital to thoroughly eliminate all traces of oil and oxides. Utilize either cutting-edge mechanical or chemical cleaning methods. This pivotal step is essential for attaining optimal welding results, ensuring the highest quality and precision.
Interpass Temperature: Diligently maintain an interpass temperature of ≤150°C to deftly prevent the formation of carbide precipitation, which could potentially compromise the weld's integrity. This precaution is paramount to achieving durable and robust welds.
Table 2: Standardized Welding Parameters for Optimal Performance - A detailed guide to ensure your welding endeavors meet the highest standards of quality and excellence.
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas - Critical parameters for achieving precision in welding.
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon: This setup provides exceptional precision and controlled welding, making it ideal for delicate tasks that require the utmost accuracy.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium: Enhance penetration and stability with this carefully balanced gas mixture, designed to deliver superior welding performance.
Source: An essential reference point for acquiring further information.
7. Procurement and Handling Guidelines: Navigate the intricacies of acquiring and managing materials with ease using these comprehensive guidelines.
Packaging: Our products are available in versatile coils and spools with diameters ranging from 0.8 to 5.0 mm; designed for flexibility and adaptability in various welding applications. Available in convenient 10-25 kg units for seamless handling and efficient storage, simplifying your logistics.
Storage: Preserve your welding materials in a dry environment with humidity levels below 60%, effectively preventing moisture absorption that could detrimental affect weld quality, ensuring long-term reliability.
8. Common Challenges & Their Effective Solutions: Overcome potential obstacles with informed strategies to maintain impeccable welding standards.
Porosity: This common issue often arises from gas impurities, but fear not, solutions are at hand. → Ensure the use of high-purity argon (99.99%) to meticulously eliminate impurities, paving the way for flawless, immaculate welds that meet the highest standards.
Hot Cracking: Skillfully mitigate this risk by employing low heat input and minimizing joint restraints, thereby preserving the integrity and resilience 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 |
