ERNiFeCr-1
1. Introducing a revolutionary nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system), meticulously crafted for high-performance tasks in the most corrosive and extreme thermal environments. This exceptional welding rod aligns with AWS classification A5.14 ERNiFeCr-1, and is internationally recognized as SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), ensuring consistent, superior quality.
Key Advantages:
Corrosion Resistance: Masterfully designed to excel in reducing media like sulfuric and phosphoric acids, while adeptly resisting stress corrosion cracking, pitting, and crevice corrosion, offering unmatched protection.
Thermal Stability: Engineered to maintain mechanical integrity across a vast temperature range, from cryogenic conditions up to a searing 900°C, ensuring reliability under thermal stress.
Versatility: Perfectly suited for seamlessly welding dissimilar metals, such as nickel alloys to steel, and excels in cladding operations, offering a dynamic range of applications.
2. Chemical Composition
The ERNiFeCr-1 composition (refer to Table 1) is precisely optimized to ensure superior weld integrity and performance:
High Nickel (38-46%) and Iron (≥22%): Form a robust, ductile matrix, balancing thermal expansion with strength for a resilient weld.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These elements significantly bolster oxidation resistance and stability, especially in challenging chloride and sulfide environments.
Low Carbon (≤0.05%) and minimal impurities work in harmony to reduce intergranular corrosion risks, enhancing the durability of the weld.
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: Boasting a formidable ≥550 MPa, this ensures compliance with AWS A5.14 minimum standards.
Elongation: With a range of ~25-34%, this welding rod offers exceptional ductility, proving its flexibility and toughness.
Impact Toughness: Expertly retains its properties even in sub-zero environments, perfect for critical structures like cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Stringently mandates chemical and mechanical specifications to maintain quality.
ISO 18274: Represents global standardization (SNi8065), ensuring international compatibility and trust.
F-Number 45 (ASME IX): This qualification underscores its suitability for welding procedures in pressure vessel fabrication.
Quality Control: Essential Material Test Certificates (MTC) and rigorous RT/PT nondestructive testing ensure the reliability of each product.
5. Applications
Primary Use: Specifically engineered for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, offering unparalleled compatibility.
Critical Industries:
Petrochemical: Ideal for reactors and acid-processing equipment, where durability and resistance are paramount.
Nuclear: Perfectly suited for steam generator tubes and pressure vessels, ensuring safety and longevity.
Aerospace: Designed for turbine components that endure rigorous thermal cycling, ensuring performance and robustness.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, providing an ideal environment for precision joints, such as those in thin tubes. Perfect for applications demanding meticulous attention to detail and superior joint quality.
MIG (GMAW): Achieve superior welds with exceptional penetration when working on thicker sections using an optimal argon-helium blend mixed at a 75%-25% ratio. This powerful combination not only guarantees robust weld quality but also significantly enhances the structural integrity of your projects.
Parameters Overview (Refer to Table 2 for detailed specifications):
Preheat/Cleaning: To ensure impeccable surface preparation for optimal welding results, it is imperative to eliminate all traces of oil and oxides. Utilize mechanical or chemical cleaning methods to achieve a pristine surface, which is crucial for superior weld outcomes.
Interpass Temperature: Carefully maintain a temperature at or below ≤150°C to prevent the formation of carbide precipitation. This meticulous control is essential to uphold the weld's integrity and ensure long-lasting performance.
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 delivers precise and controlled welding, ensuring immaculate results.
MIG 0.9-1.6 150-250 26-33 Blend of 75% Argon + 25% Helium offers enhanced penetration and welding stability.
Source:
7. Procurement and Handling Guidelines
Packaging: Choose from a versatile selection of coils and spools, available in diameters ranging from 0.8 to 5.0 mm, tailored to meet diverse welding needs. Select from convenient 10-25 kg units designed for effortless handling and efficient storage, making the welding process more streamlined.
Storage: Ensure your welding rods are stored in an arid environment with humidity levels kept below 60%. This precaution prevents moisture absorption that could potentially compromise weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Often attributed to the presence of gas impurities presents a challenge to weld integrity. → Combat porosity by utilizing high-purity argon (99.99%) to effectively eliminate impurities and achieve pristine, flawless welds.
Hot Cracking: Mitigate the risk by employing strategies such as low heat input and minimizing joint restraints. These measures help maintain the integrity of the weld and ensure long-lasting durability.
| 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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