ERNiFeCr-1
1.It is a premier nickel-based welding wire (Ni-Cr-Fe-Mo-Cu system), meticulously engineered for applications demanding the pinnacle of performance, particularly in corrosive and extreme thermal environments. Proudly classified under AWS A5.14 as ERNiFeCr-1, this welding wire is also known globally as SNi8065 (ISO 18274) and NiFe30Cr21Mo3 per the European standards, ensuring universal recognition.
Key Advantages:
Corrosion Resistance: Demonstrates exceptional proficiency in reducing media like sulfuric and phosphoric acids, and showcases robust resistance against stress corrosion cracking, pitting, and crevice corrosion.
Thermal Stability: Delivers remarkable mechanical integrity spanning from the frigid temperatures of cryogenic environments to an impressive 900°C.
Versatility: Expertly caters to the welding of dissimilar metals, such as nickel alloys to steel, and excels in cladding operations, offering versatile solutions.
2. Chemical Composition
The composition of ERNiFeCr-1 is thoughtfully optimized to ensure superior weld integrity as detailed in Table 1 below:
High Nickel (38-46%) and Iron (≥22%): These elements come together to create a ductile matrix, providing an exquisite balance of thermal expansion and strength.
Chromium (19.5-23.5%) and Molybdenum (2.5-3.5%): These enhance both oxidation resistance and stability in challenging environments such as those containing chlorides and sulfides.
Low Carbon (≤0.05%) and Impurities: Carefully minimized to reduce risks of intergranular corrosion, ensuring long-term durability.
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: An impressive ≥550 MPa, conforming with the stringent AWS A5.14 minimum standards.
Elongation: Approximately 25-34%, showcasing remarkable ductility.
Impact Toughness: Maintains robust mechanical properties in sub-zero environments, making it ideal for applications like cryogenic storage tanks.
4. Technical Standards and Certification
Governed by:
AWS A5.14/ASME SFA-5.14: Enforces rigorous chemical and mechanical specifications.
ISO 18274: Ensures global standardization, denoted as SNi8065.
F-Number 45 (ASME IX): Qualifies welding procedures for critical pressure vessels.
Quality Control: Demands the presence of Material Test Certificates (MTC) and successful completion of RT/PT nondestructive testing to assure quality.
5. Applications
Primary Use: Ideal for welding INCOLOY 825 (UNS N08825) and other similar high-performance Ni-Fe-Cr-Mo-Cu alloys.
Critical Industries:
Petrochemical: Perfect for reactors and acid-processing equipment, ensuring reliability in harsh conditions.
Nuclear: Essential for steam generator tubes and pressure vessels, offering unmatched performance.
Aerospace: Integral for turbine components that endure rigorous thermal cycling.
6. Welding Process Guidelines
Methods:
TIG (GTAW): Utilizes 100% argon shielding, making it the method of choice for precision joints, such as those found in thin tubes. ideal for precision joints (e.g., thin tubes) .
MIG (GMAW): Elevate your welding efforts with an argon-helium blend, mixed in a precise 75%-25% ratio. This potent combination not only ensures superior, deeper penetration in thicker sections but also guarantees robust weld quality and enhanced structural integrity.
Parameters Overview: For a comprehensive understanding of the specifications, please refer to Table 2.
Preheat/Cleaning: Achieve optimal welding results by meticulously removing any traces of oil and oxides through either mechanical or chemical cleaning methods. This crucial step promises a pristine surface, setting the stage for exceptional welding outcomes.
Interpass Temperature: Diligently maintain a temperature of ≤150°C. This careful temperature management is critical to prevent the formation of carbide precipitation, thereby safeguarding the weld's integrity and durability.
Table 2: Standardized Welding Parameters for Achieving Optimal Performance Excellence
Process Diameter (mm) Current (A) Voltage (V) Shielding Gas
TIG 0.9-3.2 60-220 (DCEN) 12-20 100% Argon for exceptional precision and controlled welding performance.
MIG 0.9-1.6 150-250 26-33 With a 75% Argon + 25% Helium blend, expect advanced penetration and steadfast stability.
Source:
7. Procurement and Handling Guidelines
Packaging: Tailored to your needs, available in coils and spools with diameters ranging from 0.8 to 5.0 mm; designed for efficiency and ease of use. Available in practical 10-25 kg units, ensuring easy handling and convenient storage.
Storage: Preserve the quality of your welding wire by storing it in a dry environment, maintaining humidity levels below 60% to prevent moisture absorption that could compromise weld quality.
8. Common Challenges & Their Effective Solutions
Porosity: Often caused by gas impurities that can be detrimental to weld integrity. → Ensure the use of ultra-pure argon (99.99%) to effectively eliminate impurities and achieve flawless welds.
Hot Cracking: Mitigate this risk through the application of low heat inputs and minimizing joint restraints, ensuring the preservation of 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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