ERNiFeCr-1
1. This is a meticulously designed nickel-based welding wire, crafted using the highly reputable Ni-Cr-Fe-Mo-Cu system, to cater to high-performance applications. It excels in corrosive environments and withstands extreme thermal conditions with unmatched resilience. The ERNiFeCr-1 proudly belongs to the AWS classification A5.14 ERNiFeCr-1. It is not only synonymous with SNi8065 according to ISO 18274 but also matches the European standard identifier NiFe30Cr21Mo3, making it a globally recognized welding solution.
Key Advantages:
Corrosion Resistance: This rod excels in corrosive environments, particularly effective against reducing media such as sulfuric and phosphoric acids. It provides superior resistance against stress corrosion cracking, pitting, and crevice corrosion, ensuring long-lasting durability.
Thermal Stability: Demonstrates remarkable thermal stability by maintaining mechanical integrity across a vast temperature range, from cryogenic lows to searing highs of up to 900°C.
Versatility: Highly adaptable, it is perfect for welding diverse metals, including the joining of nickel alloys to steel, and is also ideal for cladding operations.
2. Chemical Composition
The composition of ERNiFeCr-1, detailed in Table 1, is carefully optimized to ensure superior weld integrity and performance.
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix that balances thermal expansion with robust strength, ensuring reliability.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These components enhance the rod's oxidation resistance and stability, especially in harsh chloride and sulfide environments.
Low Carbon (≤0.05%) and Impurities: Specifically engineered to minimize risks of intergranular corrosion, enhancing longevity.
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: The rod boasts an impressive tensile strength of ≥550 MPa, comfortably meeting the stringent AWS A5.14 minimum standards.
Elongation: Offers an elongation range of approximately 25-34%, showcasing its excellent ductility and flexibility.
Impact Toughness: The rod retains its core properties even in sub-zero environments, making it ideal for cryogenic storage tank applications.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate rigorous chemical and mechanical specifications to ensure product excellence.
ISO 18274: Facilitates global standardization under the designation SNi8065, ensuring worldwide applicability.
F-Number 45 (ASME IX): Critical for qualifying welding procedures for pressure vessels, ensuring high safety standards.
Quality Control: Adherence to quality is paramount, requiring Material Test Certificates (MTC) and passing rigorous RT/PT nondestructive testing protocols.
5. Applications
Primary Use: Specifically developed for welding INCOLOY 825 (UNS N08825) and other similar Ni-Fe-Cr-Mo-Cu alloys, ensuring seamless and robust joints.
Critical Industries:
Petrochemical: Essential for constructing reactors and acid-processing equipment, providing durability and reliability.
Nuclear: Plays a pivotal role in fabricating steam generator tubes and pressure vessels, where safety and precision are critical.
Aerospace: Integral for manufacturing turbine components that endure thermal cycling, contributing to enhanced performance and longevity.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Employs 100% argon shielding, making it the ideal choice for precision joints, particularly in applications involving thin tubes. The method is perfect for achieving high-precision welds, ensuring flawless and durable joints.
MIG (GMAW): For achieving superior and deeper penetration in thicker sections, it is recommended to use an argon-helium blend in a precise 75%-25% ratio. This expertly crafted combination ensures robust weld quality while significantly enhancing the structural integrity of your work.
Parameters Overview (Please refer to Table 2 for the in-depth and detailed specifications):
Preheat/Cleaning: Eliminating any traces of oil and oxides is imperative. Utilize either mechanical or chemical cleaning methods to achieve a pristine surface, which is essential for optimal welding results and maintaining the highest standards of quality.
Interpass Temperature: It is crucial to meticulously maintain a temperature of ≤150°C. This precise control helps in preventing the formation of carbide precipitation, thereby safeguarding the weld's structural integrity.
Table 2: Standardized Welding Parameters for Ensuring Optimal Performance
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2 60-220 (DCEN) 12-20 Employ 100% Argon for precise and expertly controlled welding operations.
MIG 0.9-1.6 150-250 26-33 Utilize a 75% Argon + 25% Helium mixture for enhanced penetration and welding stability.
Source:
7. Procurement and Handling Guidelines
Packaging: Our products are available in coils and spools, with diameters ranging from 0.8 to 5.0 mm, tailored for your convenience. Offered in convenient 10-25 kg units to facilitate easy handling and efficient storage.
Storage: Ensure storage in a dry environment with humidity levels maintained below 60%. This precaution prevents any moisture absorption that could adversely affect weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Often attributable to gas impurities. → To eliminate impurities and achieve flawless welds, ensure the use of high-purity argon (99.99%).
Hot Cracking: Mitigate this 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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