ERNiFeCr-1
1. It is a nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system) meticulously engineered for high-performance applications in the most challenging corrosive and extreme thermal environments. This welding wire offers unparalleled durability and reliability. The product is classified under AWS classification A5.14 ERNiFeCr-1 and is synonymous with SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard). It is recognized globally for its superior performance and quality.
Key Advantages:
Corrosion Resistance: This welding wire excels in environments with reducing media such as sulfuric and phosphoric acids, and it robustly resists stress corrosion cracking, pitting, and crevice corrosion, promising longevity and reliability.
Thermal Stability: ERNiFeCr-1 maintains mechanical integrity across a broad range of temperatures, from cryogenic levels up to a remarkable 900°C, ensuring consistent performance.
Versatility: Exceptionally versatile, it is well-suited for welding dissimilar metals, such as nickel alloys to steel, and is ideal for cladding operations, making it a versatile choice for various industrial applications.
2. Chemical Composition
ERNiFeCr-1's composition, as detailed in Table 1, is optimized to ensure weld integrity and superior performance:
High Nickel (38-46%) and Iron (≥22%): These elements form a robust, ductile matrix that balances thermal expansion and strength, providing exceptional ductility and toughness.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These elements significantly enhance oxidation resistance and stability, particularly in environments rich in chlorides and sulfides.
Low Carbon (≤0.05%) and minimal impurities: These factors play a critical 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, meeting and exceeding AWS A5.14 minimum standards, assuring reliability in demanding applications.
Elongation: With an elongation of approximately 25-34%, it offers excellent ductility, making it ideal for dynamic and high-stress environments.
Impact Toughness: Retains impressive properties even in sub-zero environments, such as those found in cryogenic storage tanks, ensuring safety and durability.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: These standards mandate precise chemical and mechanical specifications, ensuring product quality and consistency.
ISO 18274: Provides global standardization under the SNi8065 designation, promising international compatibility and recognition.
F-Number 45 (ASME IX): Qualifies and certifies welding procedures for use in pressure vessels, ensuring compliance with industrial standards.
Quality Control: Requires thorough Material Test Certificates (MTC) and passes rigorous RT/PT nondestructive testing to guarantee product excellence.
5. Applications
Primary Use: Specifically designed for welding INCOLOY 825 (UNS N08825) and other similar Ni-Fe-Cr-Mo-Cu alloys, offering high-performance welding solutions.
Critical Industries:
Petrochemical: Perfect for reactors and acid-processing equipment, providing reliable and long-lasting performance.
Nuclear: Ideal for steam generator tubes and pressure vessels, meeting the stringent demands of the nuclear industry.
Aerospace: Suitable for turbine components exposed to thermal cycling, ensuring safety and efficiency under extreme conditions.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding; it's the ideal method for precision joints, such as those found in thin tubes, offering precision and quality. Perfectly suited for precision joints, ensuring the highest levels of quality and reliability in every weld.
MIG (GMAW): Achieve exceptional weld penetration with our recommended argon-helium blend at a precise 75%-25% ratio, specially formulated for thicker sections. This combination guarantees superior weld quality, ensuring remarkable structural integrity and durability.
Parameters Overview (Refer to Table 2 for detailed specifications):
Preheat/Cleaning: Prioritize the complete removal of oil and oxides through meticulous mechanical or chemical cleaning processes. This crucial step is fundamental for achieving a spotless surface, paving the way for optimal welding performance and flawless results.
Interpass Temperature: Diligently maintain an interpass temperature of ≤150°C to effectively prevent the undesirable formation of carbide precipitation, thereby safeguarding the weld's strength and reliability.
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 for precise and controlled welding, ensuring superior quality and precision.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium for enhanced penetration and stability, delivering exceptional performance on demanding tasks.
Source:
7. Procurement and Handling Guidelines
Packaging: Available in versatile coils and spools, with diameters ranging from 0.8 to 5.0 mm, tailored to meet diverse welding needs; Available in convenient units ranging between 10 and 25 kg, designed for seamless handling and efficient storage, facilitating ease of use.
Storage: Maintain a dry environment with humidity levels consistently below 60% to prevent moisture absorption, which is crucial to preserving weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Typically caused by impurities in the shielding gas. → Ensure the utilization of high-purity argon (99.99%) to thoroughly eliminate impurities, thus achieving impeccable and flawless welds.
Hot Cracking: Mitigate risks by applying low heat inputs and reducing joint restraints, upholding the weld's structural integrity and reliability.
| 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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