ERNiFeCr-1
1. Introducing a groundbreaking nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system) tailored for exceptional performance in challenging corrosive and extreme thermal environments. This prestigious wire is classified under AWS A5.14 ERNiFeCr-1, and shares its status with SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), epitomizing global recognition.
Key Advantages:
Corrosion Resistance: Masterfully engineered to excel in reducing media, like sulfuric and phosphoric acids, while offering robust defense against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Endures extreme temperatures, maintaining mechanical integrity from cryogenic lows to a blistering 900°C.
Versatility: This remarkable wire is adept at welding dissimilar metals, such as nickel alloys to steel, as well as performing expert cladding operations.
2. Chemical Composition
ERNiFeCr-1's sophisticated formula (Table 1) is crafted for superior weld integrity:
High Nickel (38-46%) and Iron (≥22%): These elements create a ductile matrix, expertly balancing thermal expansion and strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): They significantly boost oxidation resistance and ensure stability in environments containing chlorides and sulfides.
Low Carbon (≤0.05%) and Minimal Impurities: These aspects play a crucial role in 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: Achieves an impressive ≥550 MPa, perfectly aligning with AWS A5.14 minimum standards.
Elongation: Exhibits outstanding ductility with ~25-34% elongation.
Impact Toughness: Maintains formidable properties, even in cryogenic environments like storage tanks at sub-zero temperatures.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards ensure rigorous chemical and mechanical specifications are met.
ISO 18274: Offers global standardization under SNi8065, reinforcing international acceptance.
F-Number 45 (ASME IX): Essential for qualifying welding procedures in critical pressure vessel applications.
Quality Control: Demands Material Test Certificates (MTC) and successful completion of comprehensive RT/PT nondestructive testing.
5. Applications
Primary Use: Perfect for welding INCOLOY 825 (UNS N08825) and other comparable Ni-Fe-Cr-Mo-Cu alloys.
Critical Industries:
Petrochemical: Essential for reactors and acid-processing equipment.
Nuclear: Utilized in steam generator tubes and pressure vessels.
Aerospace: Ideal for turbine components subjected to thermal cycling.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Employs 100% argon shielding; specifically designed for precision welding in applications like thin-walled tube joints.
MIG (GMAW): Achieve exceptional weld quality and reinforce structural integrity by using a 75%-25% argon-helium blend. This precise combination delivers superior penetration, especially in thicker sections, ensuring robust and reliable results in every project.
Parameters Overview (Refer to Table 2 for in-depth specifications that guide you to optimal welding performance):
Preheat/Cleaning: To guarantee a flawless welding surface, it is imperative to remove all traces of oil and oxides. Utilize either mechanical or chemical cleaning methods to achieve a pristine surface, thereby ensuring excellent welding results.
Interpass Temperature: Carefully maintain a temperature of ≤150°C to prevent the formation of carbide precipitation. This diligent control is essential to uphold the weld's integrity and ensure a high-quality finish.
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 Utilize 100% Argon for unparalleled precision and controlled welding outcomes.
MIG 0.9-1.6 150-250 26-33 Opt for a 75% Argon + 25% Helium mix to achieve enhanced penetration and stability, ensuring superior weld quality.
Source:
7. Procurement and Handling Guidelines
Packaging: Offered in both coils and spools with diameters from 0.8 to 5.0 mm, tailored to meet varying project needs. Available in user-friendly 10-25 kg units for effortless handling and storage, optimizing convenience.
Storage: Ensure storage in a dry setting with humidity levels below 60% to prevent moisture absorption, which could potentially compromise weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: This issue often arises due to gas impurities, it's essential to tackle it effectively. → Employ high-purity argon (99.99%) to eradicate impurities and achieve impeccable, flawless welds.
Hot Cracking: Mitigate this risk by utilizing low heat input and minimizing joint restraints, thereby preserving weld 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 |
Audited Supplier 
){kind=link}