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Click here - Suggestions for Welding Nickel & High Nickel Alloys
Suggestions for Welding Nickel & High Nickel Alloys back to top
Nickel and High Nickel Alloys are used in fabrication of equipment which have to withstand highly corrosive environments. Often the corrosion is enhanced by the operating conditions of high pressure and temperature. Various high nickel alloys are developed and are being developed to meet these demanding conditions. In some cases the mild and low alloy steel equipment and vessels are clad by nickel alloys to combat corrosion.
Techalloy Company, Inc. Baltimore Welding Division manufactures nickel and nickel alloy welding consumables for TIG, MIG, SAW and SMAW processes.
Welding of nickel is different from welding other metals and alloys. Two characteristics contribute to this difference:
(1) Nickel could form a tenacious viscous oxide during welding which restricts the wettability and flow of the weld metal.
(2) Nickel is highly susceptible to embrittlement by sulfur, phosphorus, lead and other low-melting substances. The weld metal flow problem can be reduced by:
Selecting an appropriate joint design.
Choosing the correct type of gas and gas flow rate to ensure proper protection from atmospheric oxygen.
Clean welding consumables which do not contain any lubricants or oxides or contaminants.
Selecting a superior formulated covered electrode to ensure proper flow and cleanliness.
The weld area on both sides of the weld joint must be tightly grounded to remove oxide from the surface. Interpass cleaning is essential to ensure complete slag removal as well as fusion between the weld beads.
Weld joint designs used for nickel alloy welding should be different from those used for welding steels. The sluggish nature of the weld metal calls for more open joint which will provide better accessibility to the welder. Another characteristic of nickel alloy weld metal is the lower penetration, which makes the joints necessary to use smaller land at the root of the joint. For joining tubes and pipes, they should be purged and filled with inert gas before welding to avoid oxidation at the root. For manual welding, appropriate current range should be used to avoid overheating. Overheating of the electrode could result in loss of deoxidizers and breakdown of the binder of the flux leading to defective welding. MIG welds calls for helium additions to argon to improve the wetting of the weld metal. For TIG welding, argon or argon-helium mixtures are generally used. Gas flow rates of 30 to 50 CFH are required to obtain high quality welds. With submerged arc welding, the flux has to be pre-baked before welding to reduce the chanced of weld defects due to moisture. A procedure test is generally required to assure that the proposed welding parameters and filler metals result in sound and acceptable chemical and mechanical properties of the welds.
As the cleanliness of the welding consumables is of paramount importance, Techalloy Company, Inc. Baltimore Welding Division has incorporated in-line cleaning systems to ensure the requisite degree of cleanliness. The wires are so clean that we imprint out TIG wires with grade, heat number and size.
In the following pages you will find the description of the products, their typical chemical composition, typical mechanical properties. Should you need to have more information or discuss applications or welding parameters, do not hesitate to contact us. Sales Department e-mail.
AWS A5.15 ERNiCl back to top
ERNiCl is used for TIG and MIG welding of cast iron. This wire is extensively employed to repair gray iron casting. It can be used for overlay and buildup. However, dilution from the casting influences the mechanical properties of the metal. The welds are easily machinable.
A preheat and interpass temperature of 350 degrees F (175 degrees C) minimum is recommended during welding.
Typical Chemical Composition of the wire :
Carbon .05 Manganese .22 Silicon .05 Nickel 99.6Mechanical Properties of all weld metal (as welded) :
Tensile Strength 66,500 PSI 460 MPA Yield Strength 36,000 PSI 250 MPA Elongation 40%
AWS A5.14 ERNi-1 back to top
This wire is used for TIG, MIG and SAW welding of nickel 200 or 201. This filler metal is also employed for overlaying on steel as well as repairing cast iron castings. It can also be used for dissimilar joints between nickel or nickel alloys to stainless or ferritic steels.
Typical Chemical Composition of the wire :
Carbon .06 Manganese .30 Silicon .40 Iron .10 Sulfur .003 Phosphorus .008 Copper .02 Aluminum .5 Titanium 3.0 Nickel 95.5Mechanical Properties of all weld metal (as welded) :
Tensile Strength 66,500 PSI 460 MPA Yield Strength 38,000 PSI 260 MPA Elongation 28%
This wire is used for welding of materials of similar chemical composition (USN Number N10276), as well as dissimilar materials of nickel base alloys, steels and stainless steels. This wire also can be used for cladding steel with nickel-chromium-molybdenum weld metal.
This alloy, due to its high molybdenum content, offers excellent resistance to stress corrosion cracking, pitting and crevice corrosion.
Typical Chemical Composition of the wire :
Carbon .01 Manganese .55 Silicon .04 Chromium 15.55 Molybdenum 16.1 Tungsten 3.65 Sulfur .002 Phosphorus .009 Vanadium .15 Nickel Balance Iron 5.5Mechanical Properties of all weld metal (as welded) :
Tensile Strength 105,000 PSI 720 MPA Yield Strength 81,000 PSI 560 MPA Elongation 40%ERNiCu-7 is used for TIG, MIG and oxy-fuel welding of 70/30, 80/20 and 90/10 copper-nickel alloys. This filler metal can be used for MIG overlay on steel after a first layer with nickel 208 (Filler Metal 61). Dissimilar-welding applications include joining copper-nickel alloys to Nickel 200 or nickel-copper alloys.
Typical Chemical Composition of the wire :
Nickel 31.0 Manganese .75 Silicon .10 Phosphorus .006 Iron .55 Titanium .35 Copper BalanceMechanical Properties of all weld metal (as welded) :
Tensile Strength 53,000 PSI 360 MPA Yield Strength 21,000 PSI 140 MPA Elongation 32%ERNiCrFe-5 is used for TIG, MIG and SAW welding of nickel-chromium iron alloys such as ASTM B163, B166, B167 and B168 (UNS Number N06600). Columbium content in the alloy makes it less sensitive to cracking, especially while welding thick materials where higher stresses are encountered.
Typical Chemical Composition of the wire :
Carbon .03 Manganese .45 Silicon .20 Iron 7.5 Chromium 16.2 Columbium+ Tantalum 2.2 Nickel Balance Sulfur .002 Phosphorus .005Mechanical Properties of all weld metal (as welded) :
Tensile Strength 86,500 PSI 600 MPA Yield Strength 50,500 PSI 350 MPA Elongation 37%ERNiCr-3 is used for TIG, MIG and SAW welding of base materials such as ASTM B163, B166, B167 and B168 alloys which have UNS Number N06600. It is one of the most used nickel alloys whose applications range from cryogenic to high temperatures. This filler metal can also be used for dissimilar welding applications between various nickel alloys and stainless or carbon steels, as well as for overlaying.
Typical Chemical Composition of the wire :
Carbon .03 Manganese 2 .85 Silicon .22 Iron 1.1 Chromium 20.4 Columbium+ Tantalum 2.5 Nickel 72.9 Sulfur .001 Phosphorus .003Mechanical Properties of all weld metal (as welded) :
Tensile Strength 86,000 PSI 590 MPA Yield Strength 52,000 PSI 360 MPA Elongation 38%ERNiCrCoMo-1 is used for TIG, MIG and SAW welding of nickel-chrome-cobalt-molybdenum alloys, as well as between themselves and dissimilar metals such as stainless, carbon or low alloy steels. The filler wire also can be used for overlay welding wire similar chemical composition is desired.
The weld metal provides optimum strength and oxidation resistance from 1500 degrees F (815 degrees C) up to 2100 degrees F (1150 degrees C).
Typical Chemical Composition of the wire :
Carbon .06 Manganese .20 Silicon .11 Iron .75 Chromium 21.8 Cobalt 12.45 Molybdenum 9.05 Aluminum 1.25 Tantalum .25 Nickel Balance Sulfur .001 Phosphorus .005Mechanical Properties of all weld metal (as welded) :
Tensile Strength 112,000 PSI 770 MPA Yield Strength 88,500 PSI 610 MPA Elongation 28%ERNiCrMo-10 is an alloy of nickel with chromium molybdenum and tungsten as principal alloying elements. It is used to weld alloys of similar composition as well as dissimilar joints between nickel-chromium-molybdenum alloys and stainless or carbon or low alloy steels. It can also be used for cladded overlay as well as spraying applications. ERNiCrMo-10 offers excellent corrosion resistance in oxidizing as well as reducing media in a wide variety of chemical process environments. It offers an outstanding resistance to stress corrosion cracking, pitting and crevice corrosion.
Typical Chemical Composition of the wire :
Carbon .008 Manganese .02 Silicon .04 Iron 3.1 Sulfur .002 Phosphorus .005 Chromium 21.5 Molybdenum 13.5 Tungsten 3.5 Nickel BalanceMechanical Properties of all weld metal (as welded) :
Tensile Strength 115,000 PSI 790 MPA Yield Strength 82,000 PSI 570 MPA Elongation 38%ERNiCrMo-3 LOW IRON is used for TIG, MIG and SAW welding of nickel-chrome-molybdenum alloys. This filler metal is very versatile in its applications. It can be used for welding of dissimilar joints between nickel-chrome-molybdenum alloys and stainless or carbon or low alloy steels. It can also be used for cladding as well as for spraying applications. Techalloy 625 with low iron (less than 0.8% is preferred in various applications where dilution of iron must be controlled to the minimum.
The high alloy content of ERNiCrMo-3 enables it to withstand highly corrosive environments. The combination of nickel and chromium provides the resistance to oxidizing conditions and the combination of nickel and molybdenum provides resistance to reducing conditions. Due to its molybdenum content, this alloy offers resistance to stress corrosion cracking, pitting and crevice corrosion.
Typical Chemical Composition of the wire :
Carbon .009 Manganese .05 Silicon .12 Chromium 21.9 Molybdenum 8.65 Columbium+ Tantalum 3.7 Titanium .19 Aluminum .17 Sulfur .002 Phosphorus .006 Nickel Balance Iron .62Mechanical Properties of all weld metal (as welded) :
Tensile Strength 114,500 PSI 790 MPA Yield Strength 85,000 PSI 590 MPA Elongation 35%ERNiFeCr-2 is used for TIG welding Inconel alloy 718, 706 and X-750. It is mainly used for welding high-strength aircraft components, and liquid rocket components involving cryogenic temperatures. High heat input processes such as MIG welding often result in micro fissuring. This alloy can be age hardened to higher strengths.
Typical Chemical Composition of the wire :
Carbon .04 Manganese .25 Silicon .2 Chromium 19.0 Molybdenum 3.1 Columbium+ Tantalum 5.05 Titanium .9 Aluminum .4 Sulfur .001 Phosphorus .004 Nickel Balance Iron 17.55Mechanical Properties of all weld metal (as welded) :
Tensile Strength 125,000 PSI 860 MPA Yield Strength 91,000 PSI 630 MPA Elongation 27%ERNiFeCr-1 is used for TIG, MIG and SAW welding of nickel-iron-chromium-molybdenum-copper alloys. This can also be used to overlay cladding where similar chemical composition is required.
Typical Chemical Composition of the wire :
Carbon .03 Manganese .45 Silicon .35 Iron 29.80 Sulfur .002 Phosphorus .005 Chromium 21.5 Molybdenum 3.3 Copper 2.2 Nickel 42.0Mechanical Properties of all weld metal (as welded) :
Tensile Strength 88,500 PSI 610 MPA Yield Strength 61,000 PSI 420 MPA Elongation 34%