ERNiFeCr-1
1.It is a revolutionary nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system) crafted meticulously for high-performance applications, designed to withstand the rigors of corrosive and extreme thermal environments. It belongs to the prestigious AWS classification A5.14 ERNiFeCr-1 and is synonymous with SNi8065 (ISO 18274) and NiFe30Cr21Mo3 (European standard), ensuring top-notch quality and reliability.
Key Advantages:
Corrosion Resistance: Boasts exceptional performance in reducing media such as sulfuric and phosphoric acids, and exhibits outstanding resistance against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Offers remarkable mechanical integrity, maintaining robustness from cryogenic temperatures all the way up to 900°C, ensuring reliability under drastic temperature variations.
Versatility: Perfectly suited for welding dissimilar metals such as nickel alloys to steel and excelling in cladding operations, making it a versatile solution for various applications.
2. Chemical Composition
ERNiFeCr-1's composition, detailed in Table 1, is meticulously optimized to ensure superior weld integrity:
High Nickel (38-46%) and Iron (≥22%): These elements form a ductile matrix that harmoniously balances thermal expansion with strength, providing unmatched durability.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These elements significantly enhance oxidation resistance and stability, especially in challenging environments like chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: Specially designed to minimize the risks of intergranular corrosion, ensuring longevity and 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: Impressive ≥550 MPa, meeting AWS A5.14 standards, ensures the wire's strength and durability.
Elongation: Approximately 25-34%, showcasing excellent ductility for demanding applications.
Impact Toughness: Maintains its robust properties even in sub-zero environments, such as cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Strictly mandates chemical and mechanical specifications to ensure high standards.
ISO 18274: Ensures global standardization as SNi8065, promoting universal compatibility.
F-Number 45 (ASME IX): Qualifies welding procedures specifically for pressure vessels, ensuring safety and reliability.
Quality Control: Requires stringent Material Test Certificates (MTC) and successful RT/PT nondestructive testing to guarantee exceptional quality.
5. Applications
Primary Use: Expertly designed for welding INCOLOY 825 (UNS N08825) and similar Ni-Fe-Cr-Mo-Cu alloys, ensuring seamless and robust connections.
Critical Industries:
Petrochemical: Integral to reactors and acid-processing equipment, providing resilience under harsh conditions.
Nuclear: Essential for steam generator tubes and pressure vessels, delivering reliability in high-stakes environments.
Aerospace: Perfect for turbine components that are exposed to intense thermal cycling, ensuring performance and safety.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, ideal for precision joints such as thin tubes, enabling intricate and accurate welding. ideal for precision joints (e.g., thin tubes) .
MIG (GMAW): Achieve unmatched, deeper penetration in thicker sections by utilizing a dynamic argon-helium blend at a 75%-25% ratio. This powerful combination guarantees not only robust weld quality but also significantly enhances the structural integrity, ensuring the longevity and durability of your welds.
Parameters Overview: For comprehensive specifications and insights, please refer to Table 2.
Preheat/Cleaning: To ensure optimal welding results, it is imperative to meticulously remove any traces of oil and oxides. This can be efficiently accomplished through mechanical or chemical cleaning methods, paving the way for a pristine surface that is vital for superior weld quality.
Interpass Temperature: Diligently maintain an interpass temperature not exceeding 150°C. This precision is crucial to prevent the formation of carbide precipitation, thereby preserving the weld's integrity and quality.
Table 2: Standardized Welding Parameters for Achieving Peak Performance
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2: Utilize a current range of 60-220 (DCEN) and a voltage range of 12-20 with 100% Argon for precise and controlled welding operations.
MIG 0.9-1.6: Employ a current range of 150-250 and a voltage range of 26-33, with a 75% Argon + 25% Helium mix for enhanced penetration and stability, ensuring reliable welding results.
Source:
7. Procurement and Handling Guidelines: Master the best practices for procuring and handling our welding rods to ensure peak performance and ease of use.
Packaging: Available in convenient coils and spools, with diameters spanning from 0.8 to 5.0 mm, tailored for a variety of welding needs. Available in practical 10-25 kg units, designed for ease of handling and storage, making your operations more efficient.
Storage: Ensure storage in a dry environment, maintaining humidity levels below 60%. This precaution prevents moisture absorption, which is crucial for maintaining superior weld quality.
8. Common Challenges & Their Effective Solutions: Navigate and overcome typical obstacles with our expert recommendations for maintaining top-tier welding results.
Porosity: Often arises due to gas impurities, impacting the weld quality. → To ensure flawless welds free from impurities, opt for high-purity argon (99.99%). This choice effectively eliminates impurities, guaranteeing exceptional weld quality.
Hot Cracking: Minimize this risk by utilizing low heat input and reducing joint restraints, thereby safeguarding and maintaining the integrity and quality of the weld.
| 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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