ERNiFeCr-1
1. Introducing a high-performance nickel-based welding wire, the ERNiFeCr-1 is designed specifically for challenging environments. This exceptional Ni-Cr-Fe-Mo-Cu system thrives in corrosive and extreme thermal conditions, making it the ideal choice for demanding applications. ERNiFeCr-1 is classified under AWS A5.14 ERNiFeCr-1, recognized equivalently as SNi8065 (ISO 18274) and NiFe30Cr21Mo3 within European standards.
Key Advantages:
Corrosion Resistance: Outstanding performance in reducing media like sulfuric and phosphoric acids. It effectively combats stress corrosion cracking, pitting, and crevice corrosion, ensuring longevity and reliability.
Thermal Stability: Unwavering mechanical integrity from cryogenic lows to impressive highs of 900°C, ensuring consistent performance across a vast temperature spectrum.
Versatility: Expertly crafted for welding dissimilar metals such as nickel alloys to steel, and highly effective in cladding operations, showcasing its multifaceted application potential.
2. Chemical Composition
Optimized for unmatched weld integrity, the chemical composition of ERNiFeCr-1 (refer to Table 1) speaks volumes of its engineering excellence:
High Nickel (38-46%) and Iron (≥22%): These elements forge a ductile matrix that harmonizes thermal expansion with formidable strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These boost oxidation resistance and provide stability against chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: Strategically minimized to reduce risks of 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: Delivering a robust performance with a minimum of 550 MPa, meeting AWS A5.14 standards.
Elongation: Exhibiting remarkable ductility with elongation values ranging from 25% to 34%.
Impact Toughness: Retains its exceptional properties even in sub-zero temperatures, making it perfect for cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Establishes comprehensive chemical and mechanical specifications.
ISO 18274: Provides a globally recognized standardization, equivalent to SNi8065.
F-Number 45 (ASME IX): Qualifies essential welding procedures for pressure vessels with precision.
Quality Control: Ensures reliability with mandatory Material Test Certificates (MTC) and passes rigorous RT/PT nondestructive testing.
5. Applications
Primary Use: Expertly designed for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, making it highly specialized for these materials.
Critical Industries:
Petrochemical: Ideal for reactors and acid-processing equipment, enhancing operational efficiency and safety.
Nuclear: Critical for steam generator tubes and pressure vessels, assuring safety and performance.
Aerospace: Perfect for turbine components facing challenging thermal cycling, ensuring reliability and performance.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilize 100% argon shielding for optimal precision, especially in delicate joints like thin tubes. ideal for precision joints (e.g., thin tubes) .
MIG (GMAW): Achieve superior, deeper penetration in thicker sections with a recommended argon-helium blend at a 75%-25% ratio. This precision mix ensures robust weld quality and significantly enhances structural integrity, making it ideal for challenging welding tasks.
Parameters Overview (Refer to Table 2 for a comprehensive exploration of detailed specifications):
Preheat/Cleaning: To achieve excellent results, it is imperative to thoroughly eliminate any traces of oil and oxides using either mechanical or chemical cleaning methods. This crucial step ensures a pristine surface, setting the stage for optimal welding performance.
Interpass Temperature: Maintain a precise temperature of ≤150°C to meticulously prevent the formation of carbide precipitation, a key factor in preserving the weld's integrity and longevity.
Table 2: Standardized Welding Parameters for Ensuring Optimal Performance and Efficiency
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon ensures precise and controlled welding, delivering consistently high-quality results.
MIG 0.9-1.6 150-250 26-33 75% Argon + 25% Helium enhances penetration and stability, optimizing weld strength and reliability.
Source:
7. Procurement and Handling Guidelines: A Reliable Approach
Packaging: Offered in versatile coils and spools with diameters ranging from 0.8 to 5.0 mm, tailored for diverse requirements; Available in user-friendly units ranging from 10-25 kg, facilitating easy handling and efficient storage.
Storage: Maintain a dry environment with humidity below 60% to prevent moisture absorption, safeguarding weld quality and prolonging product longevity.
8. Common Challenges & Their Effective Solutions: Expert Insights
Porosity: Often arises from gas impurities, impacting weld quality. → Ensure the employment of high-purity argon (99.99%) to effectively eliminate impurities, achieving flawless and resilient welds.
Hot Cracking: Mitigate the risk by utilizing low heat input and minimizing joint restraints, crucial for maintaining weld integrity and 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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