ERNiFeCr-1
1. This nickel-based welding wire, part of the Ni-Cr-Fe-Mo-Cu system, is meticulously crafted for outstanding performance in environments laden with corrosive substances and extreme temperatures. It falls under the AWS classification A5.14 ERNiFeCr-1 and is equivalent to SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), ensuring universal recognition and application.
Key Advantages:
Corrosion Resistance: Delivers exceptional performance in reducing environments like sulfuric and phosphoric acids, and effectively withstands stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Exhibits remarkable mechanical integrity across a wide temperature range, from cryogenic levels up to 900°C, making it ideal for various demanding applications.
Versatility: Perfectly suited for welding dissimilar metals, such as nickel alloys to steel, and is ideal for cladding operations, providing flexibility for complex manufacturing needs.
2. Chemical Composition
The composition of ERNiFeCr-1 (refer to Table 1) is precisely engineered for superior weld integrity and performance:
With high Nickel content (38-46%) and Iron (≥22%), it forms a ductile matrix that balances thermal expansion and mechanical strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These elements significantly enhance oxidation resistance and stability, especially in chloride and sulfide-rich environments.
Low Carbon (≤0.05%) and minimal impurities are crucial in reducing the risk of intergranular corrosion, ensuring long-term 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: Reaches a robust ≥550 MPa, meeting the stringent AWS A5.14 minimum requirements.
Elongation: Displays outstanding ductility with a range of ~25-34%, ideal for applications requiring flexibility.
Impact Toughness: Maintains its resilient properties even in sub-zero environments, making it suitable for cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards dictate the precise chemical and mechanical specifications.
ISO 18274: Ensures global standardization, known as SNi8065.
F-Number 45 (ASME IX): Authorizes welding procedures specifically for pressure vessels, ensuring safety and reliability.
Quality Control: Requires Material Test Certificates (MTC) and mandates passing rigorous RT/PT nondestructive testing to ensure top quality.
5. Applications
Primary Use: Specially designed for welding INCOLOY 825 (UNS N08825) and other related Ni-Fe-Cr-Mo-Cu alloys, ensuring optimal performance.
Critical Industries:
Petrochemical: Essential for reactors and acid-processing equipment, where durability is paramount.
Nuclear: Used in steam generator tubes and pressure vessels, handling demanding conditions with ease.
Aerospace: Perfect for turbine components that face rigorous thermal cycling, ensuring longevity and performance.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it ideal for precision joints such as thin tubes, where accuracy is crucial.
MIG (GMAW): Experience unparalleled welding excellence with an argon-helium blend in a 75%-25% ratio. This powerful combination delivers superior and deeper penetration in thicker sections, ensuring robust weld quality and fortifying structural integrity.
Parameters Overview (Refer to Table 2 for comprehensive specifications that guarantee optimal performance in various scenarios):
Preheat/Cleaning: Achieve welding perfection by eliminating all traces of oil and oxides. Employ either mechanical or chemical cleaning methods to ensure a pristine surface, essential for achieving the highest quality welding results.
Interpass Temperature: Rigorous monitoring is essential to maintain a temperature of ≤150°C. This meticulous control is crucial to prevent the formation of carbide precipitation, thereby safeguarding the weld's integrity and longevity.
Table 2: Standardized Welding Parameters for Ensuring Optimal Performance and Uncompromised Quality
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas: Tailor your welding process with precision using the parameters laid out in this guide.
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon: Utilize 100% Argon for immaculate, precise, and controlled welding, ensuring flawless execution every time.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium: Maximize welding performance with enhanced penetration and unmatched stability using this expertly balanced gas combination.
Source: Consult this section for reliable and authoritative references.
7. Procurement and Handling Guidelines: Follow these guidelines to ensure the highest standards of quality and safety in handling your materials.
Packaging: Available in versatile coils and spools, with diameters ranging from 0.8 to 5.0 mm; designed for efficiency and ease of use. Available in convenient 10-25 kg units for streamlined handling and efficient storage, making your workflow smoother and more manageable.
Storage: Preserve weld quality by storing in a dry environment with humidity levels below 60%, effectively preventing moisture absorption.
8. Common Challenges & Their Effective Solutions: Navigate potential obstacles with confidence, armed with proven solutions.
Porosity: A common challenge often arising from gas impurities that can be effectively managed. → Achieve flawless welds by ensuring the use of high-purity argon (99.99%), effectively eliminating impurities for impeccable results.
Hot Cracking: Mitigate risks by employing strategies such as low heat input and minimizing joint restraints to preserve weld integrity.
| 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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