ERNiFeCr-1
1. Introducing a high-performance nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system), this is your go-to solution for demanding applications in environments where corrosion and thermal extremes challenge other materials. This premium welding rod stands proudly in the AWS classification A5.14 ERNiFeCr-1, fully aligning with SNi8065 (ISO 18274) and boasting compliance with the stringent European standard NiFe30Cr21Mo3.
Key Advantages:
Corrosion Resistance: Unmatched capability in reducing media, including sulfuric and phosphoric acids; effectively combats stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Remarkably retains mechanical integrity across an impressive range from cryogenic conditions up to a scorching 900°C.
Versatility: Expertly designed for welding dissimilar metals, such as nickel alloys to steel, and excels in cladding operations.
2. Chemical Composition
ERNiFeCr-1's engineered composition (refer to Table 1) is meticulously crafted for superior weld integrity:
High Nickel (38-46%) and Iron (≥22%): Creates a strong, ductile matrix, ensuring balanced thermal expansion and robust strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): Augments oxidation resistance and ensures stability in chloride and sulfide environments.
Low Carbon (≤0.05%) and Controlled Impurities: Strategically minimizes the 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: An impressive ≥550 MPa, comfortably meeting the AWS A5.14 minimum requirements.
Elongation: Boasts a commendable ~25-34%, showcasing exemplary ductility.
Impact Toughness: Reliably retains its properties even in sub-zero environments such as cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Ensures adherence to strict chemical and mechanical specifications.
ISO 18274: Ensures global standardization, synonymous with SNi8065.
F-Number 45 (ASME IX): Provides qualification for welding procedures critical to pressure vessels.
Quality Control: Demands comprehensive Material Test Certificates (MTC) and successful RT/PT nondestructive testing.
5. Applications
Primary Use: Expertly crafted for welding INCOLOY 825 (UNS N08825) and akin Ni-Fe-Cr-Mo-Cu alloys.
Critical Industries:
Petrochemical: Essential for reactors and acid-processing equipment.
Nuclear: Integral for steam generator tubes and pressure vessels.
Aerospace: Vital for turbine components enduring thermal cycling.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Employs 100% argon shielding; perfect for crafting precision joints, particularly in thin tubes.
MIG (GMAW): For unrivaled penetration in thicker sections, utilize a meticulously balanced argon-helium blend at a 75%-25% ratio. This powerful combination guarantees exceptional weld quality, bolstering the structural integrity of your project for enduring durability.
Parameters Overview (Refer to Table 2 for detailed specifications):
Preheat/Cleaning: Eliminate any hint of oil and oxides with precision mechanical or chemical cleaning methods. This vital step ensures a flawless surface, setting the stage for unparalleled welding results.
Interpass Temperature: Diligently maintain a temperature of ≤150°C to prevent carbide precipitation, safeguarding the weld's integrity and ensuring a resilient, high-quality finish.
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) 12-20 100% Argon for precise and controlled welding, delivering unmatched accuracy.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium for superior penetration and enhanced stability, ensuring consistent performance.
Source:
7. Procurement and Handling Guidelines
Packaging: Available in versatile coils and spools with diameters ranging from 0.8 to 5.0 mm, catering to a wide range of welding needs; Available in convenient 10-25 kg units for seamless handling and efficient storage, streamlining your operations.
Storage: Store in a dry environment with humidity levels below 60% to avert moisture absorption, preserving weld quality for optimal results.
8. Common Challenges & Their Effective Solutions
Porosity: Commonly caused by gas impurities; a challenge that needs to be addressed with precision. → Employ high-purity argon (99.99%) to eradicate impurities, achieving impeccable and flawless welds.
Hot Cracking: Mitigate risk by using low heat input and minimizing joint restraints, ensuring weld integrity and longevity.
| 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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