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ERNi-1 Nickel Alloy Bare Wire: Versatile Filler Metal for Nickel and Dissimilar Metal Joining

2025-04-25

Introduction

ERNi-1 is a nickel alloy bare welding wire designed primarily for joining Nickel 200 (UNS N02200)and Nickel 201 (UNS N02201), including ASTM grades such as B160, B725, and B730. This alloy is also highly effective for welding dissimilar metals, including nickel alloys to stainless steels or ferritic steels, making it a versatile choice for various industrial applications. Additionally, ERNi-1 is used for overlaying carbon steel and repairing cast iron castings, ensuring strong, corrosion-resistant joints.

Key Features & Applications

Excellent Weldability

Produces high-quality, crack-free welds with good mechanical properties.

Suitable for  TIG (GTAW) and MIG (GMAW)welding processes.

Dissimilar Metal Welding

Ideal for joining nickel alloys to stainless steel or carbon steel, reducing galvanic corrosion risks.

Overlay & Repair Applications

Used for hardfacing carbon steel and repairing cast iron components in industrial machinery.

Corrosion Resistance

Maintains the high corrosion resistance of nickel-based alloys in harsh environments.

Chemical Composition (%)

The composition of ERNi-1 ensures optimal welding performance:

Element

Max (%)

Ni + Co

≥ 93

Si

≤ 0.75

C

≤ 0.15

Al

≤ 1.5

Mn

≤ 1.0

Ti

2.0–3.5

Fe

≤ 1.0

P

≤ 0.03

S

≤ 0.015

Cu

≤ 0.25

Others

≤ 0.50

The high nickel content ensures compatibility with pure nickel and nickel alloys, while controlled levels of titanium (Ti)and  aluminum (Al) enhance weld strength and crack resistance.

Mechanical Properties

Property

Value

Tensile Strength

≥ 60,000 psi (414 MPa)

Elongation

≥ 20%

These properties ensure strong, ductile welds capable of withstanding mechanical stress and thermal cycling.

Available Product Forms

ERNi-1 is supplied in:

Spooled Wire (MIG/GMAW):0.8–1.2 mm diameter

Straight Lengths (TIG/GTAW):1.2–3.2 mm diameter

The precision-wound spools ensure smooth feeding in automated welding processes.

Conclusion

ERNi-1 nickel alloy bare wire is a reliable, high-performance filler metal for welding pure nickel, dissimilar metals, and repair applications. Its excellent weldability, corrosion resistance, and mechanical strength make it a preferred choice in chemical processing, power generation, and heavy industry.

For optimal results, proper welding techniques and shielding gases (such as argon or helium for TIG) should be used to prevent contamination and ensure high-quality welds.