ERNiFeCr-1
1. It is an exceptional nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system), meticulously engineered to deliver high performance in environments subjected to corrosive elements and extreme thermal conditions. This specialized welding wire is classified under AWS A5.14 ERNiFeCr-1 and is known in the industry as SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), offering a benchmark in quality and reliability.
Key Advantages:
Corrosion Resistance: Remarkably excels in reducing media, such as sulfuric and phosphoric acids, and demonstrates superior resistance against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Maintains its structural and mechanical integrity from the lowest cryogenic temperatures up to a robust 900°C, ensuring consistent performance.
Versatility: Exceptionally suitable for welding dissimilar metals, such as nickel alloys to steel, and is ideal for various cladding operations, offering unmatched flexibility in its applications.
2. Chemical Composition
ERNiFeCr-1's meticulously optimized composition (refer to Table 1) ensures unparalleled weld integrity and performance:
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix, crucial for balancing thermal expansion with strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): Enhance oxidation resistance while providing stability in challenging chloride and sulfide environments.
Low Carbon (≤0.05%) and minimal impurities: These factors are essential to minimizing the risks associated with 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: Demonstrates impressive tensile strength of ≥550 MPa, comfortably meeting the AWS A5.14 minimum standards.
Elongation: Boasts excellent ductility with an elongation range of ~25-34%, ensuring flexibility and resilience.
Impact Toughness: Retains its exceptional properties even in sub-zero environments, making it suitable for applications like cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate stringent chemical and mechanical specifications.
ISO 18274: Global standardization under SNi8065, ensuring consistency and international recognition.
F-Number 45 (ASME IX): Qualifies welding procedures specifically for pressure vessels, highlighting its industrial applicability.
Quality Control: Requires Material Test Certificates (MTC) and must pass RT/PT nondestructive testing, ensuring the highest quality assurance.
5. Applications
Primary Use: Ideally suited for welding INCOLOY 825 (UNS N08825) and other similar Ni-Fe-Cr-Mo-Cu alloys, offering unmatched performance.
Critical Industries:
Petrochemical: Perfect for reactors and acid-processing equipment, where reliability is paramount.
Nuclear: Essential for steam generator tubes and pressure vessels, ensuring safety and durability.
Aerospace: Ideal for turbine components exposed to rigorous thermal cycling, enhancing their longevity.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it ideal for precision joints, such as those required in thin tube welding. This method is perfect for achieving top-tier precision and durability in your welding projects.
MIG (GMAW): Experience unparalleled penetration in thicker sections with our expertly crafted argon-helium blend, perfectly balanced at a 75%-25% ratio. This powerful combination not only ensures robust weld quality but also significantly enhances structural integrity, providing you with the ultimate welding performance.
Parameters Overview (Refer to Table 2 for comprehensive and detailed specifications that guide you toward optimal welding performance):
Preheat/Cleaning: Achieve the highest standards in welding by meticulously eliminating any traces of oil and oxides through either mechanical or chemical cleaning methods. This critical step is essential in preparing a pristine surface, paving the way for optimal welding results.
Interpass Temperature: Vigilantly maintain a temperature of ≤150°C to prevent the formation of carbide precipitation, thereby safeguarding the weld's integrity and ensuring long-lasting results.
Table 2: Standardized Welding Parameters for Achieving Optimal Performance and Consistent Results
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas: Tailored parameters designed for precision.
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon: Ideal for achieving precise and controlled welding, ensuring each project meets exacting standards.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium: Engineered for enhanced penetration and stability, setting new benchmarks in welding excellence.
Source: Discover the origins of excellence with our meticulously sourced materials.
7. Procurement and Handling Guidelines: Master the art of efficient procurement and handling with our expert guidelines.
Packaging: Our versatile packaging options include coils and spools with diameters ranging from 0.8 to 5.0 mm, catering to diverse welding needs. Available in convenient 10-25 kg units for effortless handling and storage, ensuring ease of use across all applications.
Storage: Preserve weld quality by storing in a dry environment with humidity levels maintained below 60%, effectively preventing moisture absorption.
8. Common Challenges & Their Effective Solutions: Overcome welding challenges with our advanced solutions for seamless operations.
Porosity: This issue often arises from gas impurities, but fear not, we have the solution. → Ensure the use of high-purity argon (99.99%) to eradicate impurities, guaranteeing flawless welds and superior craftsmanship.
Hot Cracking: Mitigate risks by employing low heat input and minimizing joint restraints, thereby maintaining weld integrity and enhancing 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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