ERNiFeCr-1
1. Introducing ERNiFeCr-1, a superior nickel-based welding wire crafted specifically for high-performance tasks in corrosive and extreme thermal environments. This wire, a member of the Ni-Cr-Fe-Mo-Cu system, showcases unparalleled durability and reliability. Proudly classified under AWS A5.14 ERNiFeCr-1, this product is also recognized by the synonymous standards SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard) for international acclaim.
Key Advantages:
Corrosion Resistance: Achieving excellence in reducing environments such as sulfuric and phosphoric acids, it effectively combats stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Demonstrates outstanding mechanical integrity from extreme cryogenic temperatures up to a searing 900°C.
Versatility: Perfectly suited for welding diverse metals, like nickel alloys to steel, and ideal for seamless cladding operations.
2. Chemical Composition
The chemical composition of ERNiFeCr-1 (refer to Table 1) is meticulously optimized to ensure weld integrity, offering a balanced structure for exceptional performance.
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix, harmonizing thermal expansion with strength for robust applications.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components enhance oxidation resistance and stability, even in challenging chloride or sulfide environments.
Low Carbon (≤0.05%) and Impurities: Designed to minimize the risks of intergranular corrosion, ensuring long-lasting reliability.
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: A robust ≥550 MPa, surpassing the AWS A5.14 minimum requirements with ease.
Elongation: Featuring an impressive ~25-34%, this wire offers outstanding ductility for dynamic applications.
Impact Toughness: Retains its remarkable properties even in sub-zero environments, such as cryogenic storage tanks, ensuring resilience and flexibility.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Dictates stringent chemical and mechanical specifications, assuring quality.
ISO 18274: Provides global standardization as SNi8065, iterating its worldwide recognition.
F-Number 45 (ASME IX): Qualifies rigorous welding procedures essential for pressure vessels.
Quality Control: Demands comprehensive Material Test Certificates (MTC) and the fulfillment of RT/PT nondestructive testing, affirming uncompromised quality.
5. Applications
Primary Use: Ideally suited for welding INCOLOY 825 (UNS N08825) and similar high-performance Ni-Fe-Cr-Mo-Cu alloys.
Critical Industries:
Petrochemical: Essential for reactors and acid-processing equipment, ensuring operational excellence.
Nuclear: Guarantees reliability in steam generator tubes and pressure vessels, vital for safety.
Aerospace: Optimized for turbine components subjected to thermal cycling, ensuring durability.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Employs 100% argon shielding, providing precision for delicate joints such as thin tubes. Ideal for precision joints (e.g., thin tubes).
MIG (GMAW): Elevate your welding prowess with an argon-helium blend in a precise 75%-25% ratio, designed for exceptional, deeper penetration in thicker sections. This powerful combination guarantees robust weld quality and significantly enhances structural integrity, ensuring your projects stand the test of time.
Parameters Overview (Refer to Table 2 for comprehensive specifications):
Preheat/Cleaning: Achieve impeccable welding results by meticulously eliminating any traces of oil and oxides. Utilize mechanical or chemical cleaning methods to ensure a flawless surface, setting the stage for optimal welding performance.
Interpass Temperature: Vigilantly maintain a temperature of ≤150°C to effectively prevent the formation of carbide precipitation, which could potentially compromise the weld's structural integrity and overall quality.
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 welding precision and control, ensuring exacting standards are met.
MIG 0.9-1.6 150-250 26-33 Blend of 75% Argon + 25% Helium for superior penetration and enhanced weld stability.
Source:
7. Procurement and Handling Guidelines
Packaging: Provided in both coils and spools, with diameters available from 0.8 to 5.0 mm, tailored to your specific project needs; Offerings available in practical 10-25 kg units, designed for easy handling and efficient storage solutions.
Storage: Preserve your welding wire's integrity by storing in a dry environment, maintaining humidity levels below 60%, preventing moisture absorption that could detrimentally affect weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Typically resulting from gas impurities, → Ensure the usage of high-purity argon (99.99%) to effectively eliminate impurities, achieving flawless welds with precision.
Hot Cracking: Mitigate risk by employing low heat input and minimizing joint restraints, thereby maintaining the weld's integrity and quality.
| 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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