MIG & TIG
ERNiCu-7 is used for MIG, TIG, and SAW welding of copper alloys. It is used for joining base materials such as UNS number NO4400, NO4405 and NO5500. This alloy can be used for dissimilar welding applications using various nickel-copper alloys to nickel 200 and to copper-nickel alloys. This alloy can be used to overlay over carbon steel, provided a buffer layer of ERNi-1 is used for the first layer.
|Condition||Tensile strength Mpa (Ksi)||Yield strength Mpa (Ksi)||Elongation %|
|AWS Reaulrement||480（70）||Not specified||Not specified|
|Typical Results as weled||530（77）||360（53）||34|
|Diameter(in）||Diameter(mm）||Process||Volt||Amps (flat)||Amps (V/OH)|
|0.035||0.9||GMAW||26-29||150-190||Spray Transfer 100% Argon|
|0.045||1.2||GMAW||28-32||180-220||Spray Transfer 100% Argon|
|1/16||1.6||GMAW||29-33||200-250||Spray Transfer 100% Argon|
|Wire For MIG/GMAW Welding||0.8mm /1.0mm /1.2mm /1.6mm /2.0mm /2.4mm /2.5mm /3.2mm||-||33 lbs (15kgs)|
|Rods For TIG/GTAW Welding||2.0mm /2.4mm /2.5mm /3.2mm /4.0mm /5.0mm||915mm- 1000mm||11 lbs (5kgs)|
|Wire For SAW Welding||2.0mm /2.4mm /2.5mm /3.2mm /4.0mm /5.0mm||-||60 lbs (27kgs)|
Overview of ERNiCu-7:
A. Composition and Alloy Properties:
ERNiCu-7 is a high-performance nickel alloy welding wire composed of nickel, chromium, iron, and other elements carefully selected to impart exceptional properties to the alloy. The precise composition is designed to achieve optimal balance, ensuring a combination of high-temperature stability, corrosion resistance, and mechanical strength.
The alloy properties of ERNiCu-7 include excellent resistance to oxidation and corrosion in various environments, making it particularly well-suited for applications in aggressive and demanding conditions. The alloy is known for its stability at elevated temperatures, maintaining its mechanical integrity under extreme thermal stress.
B. Manufacturing Process:
The manufacturing process of ERNiCu-7 involves a series of precision-controlled steps to ensure the highest quality and consistency. The raw materials undergo stringent quality checks before being melted and alloyed to the specified composition. The alloy is then processed through a carefully monitored casting and extrusion process to produce the wire with the required dimensions.
Quality control measures are implemented at every stage of production to guarantee the uniformity of the alloy’s composition and mechanical properties. Alloy 60 is produced in various forms, including wire spools and coils, to cater to the diverse needs of welding applications.
C. Compliance with Industry Standards:
ERNiCu-7 complies with industry standards and specifications to meet the stringent requirements of critical applications. The manufacturing process is carried out in accordance with international quality standards, and the product undergoes rigorous testing to ensure it meets or exceeds the specified performance criteria.
Certifications from recognized industry bodies validate the quality and reliability of ERNiCu-7, providing users with the confidence that the welding wire is engineered to the highest standards. This commitment to quality is essential for applications where precision and reliability are paramount.
Key Attributes of ERNiCu-7:
A. High Temperature Stability:
One of the standout features of ERNiCu-7 is its exceptional stability at high temperatures. This property makes it an ideal choice for applications where exposure to elevated temperatures is a constant factor, such as in the aerospace and power generation industries.
The alloy’s high-temperature stability is attributed to the synergistic effects of its alloying elements. Nickel, the primary component, contributes to the overall heat resistance of the alloy. Chromium enhances oxidation resistance, preventing the formation of detrimental oxides that could compromise the material’s integrity. This combination of elements results in a welding wire that can withstand the challenges posed by extreme temperatures, ensuring structural integrity and reliability in demanding environments.
B. Corrosion Resistance:
ERNiCu-7 exhibits outstanding corrosion resistance, making it well-suited for applications in corrosive environments commonly found in the petrochemical and marine industries. The alloy’s corrosion resistance is attributed to the presence of nickel, which forms a protective oxide layer on the surface of the material, preventing corrosive elements from reaching the underlying substrate.
The addition of chromium further enhances the corrosion resistance of ERNiCu-7. Chromium forms stable oxides that act as a barrier, preventing the penetration of corrosive agents. This dual-layer protection, facilitated by nickel and chromium, ensures long-term durability and reliability in challenging environments where corrosion is a significant concern.
Weldability is a critical factor in the performance of welding materials, and ERNiCu-7 excels in this regard. The alloy’s composition is carefully balanced to facilitate smooth and stable welding processes, resulting in high-quality and defect-free welds.
The welding characteristics of ERNiCu-7 include good arc stability, minimal spattering, and ease of control during the deposition of weld metal. These attributes make it an excellent choice for both manual and automated welding applications. Whether used in aerospace components, petrochemical equipment, or power generation infrastructure, ERNiCu-7 ensures consistent and reliable welds, contributing to the overall structural integrity of welded assemblies.
D. Mechanical Properties:
ERNiCu-7 is engineered to deliver exceptional mechanical properties, ensuring the structural integrity and longevity of welded components. The alloy exhibits a balance of strength, ductility, and toughness, making it suitable for a wide range of applications where these properties are essential.
The tensile strength of ERNiCu-7 is optimized to meet the requirements of critical applications, providing the necessary structural support under varying loads. Additionally, the alloy maintains good ductility, allowing it to undergo deformation without compromising its overall integrity. This combination of mechanical properties makes alloy 60 a versatile choice for welding applications in industries where structural performance is paramount.
E. Consistency and Quality Assurance:
Consistency is a hallmark of alloy 60, and it is achieved through rigorous quality assurance measures implemented throughout the manufacturing process. From the selection of raw materials to the final inspection of the finished product, each step is carefully monitored to ensure that every spool or coil of ERNiCu-7 meets the specified standards.
Quality control measures include chemical analysis, mechanical testing, and non-destructive testing methods to verify the alloy’s composition and performance. The commitment to quality assurance is reflected in the batch-to-batch uniformity of ERNiCu-7, providing users with a welding wire that can be relied upon for consistent and repeatable results. This level of quality assurance is particularly crucial in industries where deviations from specified parameters can have severe consequences.
Applications of ERNiCu-7:
A. Aerospace Industry:
In the aerospace industry, where components are subjected to extreme temperatures, corrosive environments, and stringent safety standards, ERNiCu-7 emerges as a material of choice for welding critical components. From engine components to structural elements, this nickel alloy welding wire contributes to the overall reliability and longevity of aerospace structures, ensuring that they withstand the demanding conditions encountered during flight.
B. Petrochemical Sector:
The petrochemical sector demands materials that can withstand corrosive chemicals, high temperatures, and challenging operating conditions. ERNiCu-7, with its superior corrosion resistance and high-temperature stability, finds applications in the fabrication of equipment such as heat exchangers, reactors, and piping systems. The alloy’s ability to maintain integrity in corrosive environments enhances the safety and reliability of petrochemical facilities.
C. Power Generation Plants:
Power generation plants, whether conventional or renewable, require materials that can endure the harsh conditions associated with electricity production. ERNiCu-7 is utilized in the fabrication of components for boilers, turbines, and heat exchangers, where it contributes to the overall efficiency and reliability of power generation systems. Its resistance to oxidation and corrosion makes it well-suited for prolonged exposure to high-temperature and high-pressure environments.
D. Marine Applications:
In marine environments, where structures are constantly exposed to saltwater and aggressive atmospheric conditions, ERNiCu-7 serves as a corrosion-resistant solution. From shipbuilding to offshore platforms, this alloy ensures the longevity and reliability of welded components, even in the challenging conditions of the open sea. Its resistance to pitting and crevice corrosion makes it a valuable asset in maritime applications.
E. Nuclear Facilities:
The nuclear industry places a premium on materials that can withstand radiation, high temperatures, and corrosive conditions. ERNiCu-7, with its combination of nickel and chromium, offers excellent corrosion resistance and stability in nuclear environments. It finds application in the fabrication of reactor components, fuel handling systems, and other critical structures within nuclear facilities, contributing to the safety and reliability of nuclear power plants.
Advantages of Choosing ERNiCu-7:
A. Enhanced Performance:
ERniCu-7 stands out in terms of performance, offering a unique combination of high-temperature stability, corrosion resistance, and mechanical strength. Its engineered composition ensures that it not only meets but often exceeds the performance requirements of critical applications, providing an added layer of confidence to engineers and fabricators.
B. Cost Efficiency:
While the initial cost of high-performance materials may be a consideration, the long-term cost efficiency of ERNiCu-7 becomes evident in its durability and resistance to degradation. The extended lifespan of components fabricated with alloy 60 reduces the need for frequent replacements and maintenance, contributing to overall cost savings in the lifecycle of structures and equipment.
C. Longevity and Durability:
ERNiCu-7 is designed for longevity, with properties that enable it to withstand the test of time in challenging environments. Its resistance to corrosion, oxidation, and high temperatures ensures that components made with ERNiCu-7 remain structurally sound and dependable over extended periods, reducing the likelihood of premature failure.
The versatility of ERNiCu-7 makes it suitable for a wide range of applications across diverse industries. Whether used in the aerospace, petrochemical, power generation, marine, or nuclear sectors, this alloy adapts to the specific demands of each application, showcasing its versatility as a go-to solution for critical welding needs.