ERCUNIAL Spooled Wire & Bare Filler Metal Rod
ERCuNiAl Spooled Wire & Bare Filler Metal Rod Welding Wire Supplier in India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified facility. Mumbai-based importer and stockist of ERCuNiAl nickel-aluminium bronze spooled wire and bare filler rods, classified under AWS A5.7 / ASME SFA-5.7 and EN ISO 24373 CuAl9Ni5Fe3Mn2.
ERCuNiAl is the high composition-matched filler metal for welding and restoring cast or wrought nickel-aluminium bronze, primarily the C95800 alloy series. This classification, which includes bare GTAW rods and spooled GMAW wire, meets military standard MIL-B-21230 Alloy 1 and ASME Section IX F-Number F-36. The metallurgical composition consists of 77–84% Cu, 8.50–9.50% Al, 4.0–5.50% Ni, 3.0–5.0% Fe, and 0.60–3.50% Mn. Nickel concentration of 4.0–5.50% strengthens the alpha-phase matrix via solid-solution hardening and makes it more resistant to seawater corrosion and high-velocity surface attacks. This filler produces high-strength deposits with a tensile strength of 718 MPa (104 ksi) and a hardness of 196 HBW, ensuring long-term structural integrity in aggressive maritime and industrial environments.
MIG spooled wire is stocked in 0.9, 1.2, and 1.6 mm diameters on 12 in (30 lb) spools; TIG bare rods from 1.6 to 4.8 mm in 914 mm (36 in) and 355 mm (14 in) lengths. A preheat of 150–200°C is recommended for base-metal sections exceeding 19 mm. It’s widely used in industries such as marine propulsion, shipbuilding, power generation, oil and gas, and desalination. Every batch ships with MTC 3.1 per EN 10204.
ERCuNiAl Nickel-Aluminium Bronze Wire and Rod Specifications
Refer to the following summary for a comprehensive overview of the technical standards and industrial specifications for ERCuNiAl.
| AWS Classification | ERCuNiAl as per AWS A5.7 / SFA-5.7 |
|---|---|
| Coated Electrode (SMAW) | ECuNiAl per AWS A5.6 |
| Processes | GTAW (TIG), GMAW (MIG) |
| Shielding Gas | 100% Argon or Ar/He |
| MIG Wire Diameters | 0.9 mm, 1.2 mm, 1.6 mm |
| TIG Rod Diameters | 1.6, 2.4, 3.2, 4.0, 4.8 mm |
| TIG Rod Lengths | 914 mm (36 in), 355 mm (14 in) |
| Test Certificate | MTC 3.1 per EN 10204 |
What Does ERCuNiAl Mean? — AWS A5.7 Classification Explained
This table indicates in-depth explanation of the AWS A5.7 alphanumeric classification system for nickel-aluminium bronze.
| Component | Meaning & Specification |
|---|---|
| E | Electrode: Indicates the filler metal is spooled wire for GMAW (MIG) processes. |
| R | Rod: Indicates the filler metal is bare rod for GTAW (TIG) processes. |
| Cu | Copper: Identifies the alloy as a copper-base filler metal (77.0%–84.0%). |
| Ni | Nickel: Significant 4.0%–5.5% addition for solid-solution hardening and seawater resistance. |
| Al | Aluminium: Primary alloying element (8.5%–9.5%) used to achieve high mechanical strength. |
ERCuNiAl is a copper-based filler (AWS A5.7) containing 4.0–5.5% nickel and 8.5–9.5% aluminium. It is engineered for GMAW (E) and GTAW (R) processes to provide high-strength, seawater-corrosion-resistant deposits for critical propeller-grade alloy restoration.
Deposit Chemical Composition of ERCuNiAl
Please see the table below for the precise elemental percentages and specific chemical concentration limits for ERCuNiAl deposits.
| Specification | Copper (Cu)* | Aluminium (Al) | Iron (Fe) | Nickel (Ni) | Manganese (Mn) | Silicon (Si) | Others (total) |
|---|---|---|---|---|---|---|---|
| Bare Wire ERCuNiAl (%) | Balance (~77–84) | 8.50–9.50 | 3.0–5.0 | 4.0–5.50 | 0.60–3.50 | 0.10 max | 0.50 max |
| Coated Electrode ECuNiAl (%) | Balance | 8.50–9.50 | 3.0–6.0 | 4.0–6.0 | 0.50–3.50 | 1.5 max | 0.50 max |
* Including silver. The coated electrode permits wider Fe and Ni ranges and higher Si max from flux constituents.
All-Weld-Metal Mechanical Properties of ERCuNiAl
Check the following table for the typical tensile strength, yield strength, and elongation metrics of ERCuNiAl.
| Specification | Tensile Strength | Yield Strength (0.2%) | Elongation (% in 50 mm) | Reduction of Area | Hardness (HBW 10/3000) |
|---|---|---|---|---|---|
| Bare Wire (ERCuNiAl) | 718 MPa (104 ksi) | 407 MPa (59 ksi) | 23% | 22% | 196 HBW |
| Coated Electrode (ECuNiAl) | 683 MPa (99 ksi) | 400 MPa (58 ksi) | 25% | 22% | 187 HBW |
Base Metal Compatibility for ERCuNiAl
Review the following list for various copper-based alloys and dissimilar metals suitable for welding with ERCuNiAl filler metal
| Base Metal | Grade / UNS | ASME P-No. | Strategic Procurement & Technical Notes |
|---|---|---|---|
| NiBral Casting | C95800 / AMPCO 45 | P35 | Primary joining and repair; uses composition-matched filler for casting integrity. |
| Wrought NiAl Bronze | C63000 / C63200 | P35 | Ideal for high-strength fabrication; fully compatible with Ni-Al bronze plate. |
| Aluminium Bronze | Other Casting Grades | P35 | Specialized repair grade offering significantly higher strength than standard ERCuAl-A2. |
| Carbon & Alloy Steel | A36 / 1018 / P11 | P1 / P3 | Applied as a cavitation-resistant overlay, specifically for critical marine service components. |
| Dissimilar Joints | NiAl Bronze to Steel | Varies | Used for high-performance transition joints in pump and valve fabrication. |
ERCuNiAl is the matched filler for all NiBral (C95800) base metals. Classification societies (DNV, ABS, Lloyds, BV) mandate composition-matched fillers for propeller repair. A preheat of 150–200°C applies for C95800 sections exceeding 19 mm.
Recommended Welding Parameters for ERCuNiAl
The table below provides optimised operational settings and specialised techniques for achieving high-quality results with ERCuNiAl consumables.
| Process / Diameter | Amperage (A) | Voltage (V) | Shielding Gas |
|---|---|---|---|
| GTAW (TIG) 2.4 mm | 150–225 | 16–20 | 100% Argon |
| GTAW (TIG) 3.2 mm | 225–300 | 18–22 | 100% Argon |
| GMAW (MIG) 1.2 mm | 200–275 | 24–28 | 100% Ar or 75% Ar/25% He |
| GMAW (MIG) 1.6 mm | 275–350 | 26–30 | 100% Ar or 75% Ar/25% He |
Specify high-amperage parameters to overcome the heat-sink effect of copper-based alloys. Use DCEP spray transfer for GMAW and DCEN for GTAW, ensuring precise voltage control to maintain a stable arc and avoid inclusions.
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Industrial Applications of ERCuNiAl Nickel-Aluminium Bronze Wire
The following are the industrial applications of ERCuNiAl Nickel-Aluminium Bronze Wire
- Propeller Restoration: Primary choice for repairing C95800 NiBral castings. It ensures welded sections meet strict maritime classification standards (DNV/ABS) for cavitation resistance and mechanical strength.
- Ship fittings: Used for sea chests, hull valves, and rudder fittings. It provides high-strength, seawater-immersed joints that match the base metal's superior corrosion resistance and durability.
- Propulsion systems: Applied to gear housings and thrust bearings in high-performance vessels. The alloy is a suitable trade-off for corrosion resistance and strength of the engine components.
- Power plant seawater systems: This alloy is used in power plant seawater intake screens and cooling system valves. Power stations near the sea need it to prevent high-velocity fluid erosion and corrosion.
- Offshore equipment: Applied to subsea valve bodies and offshore pump housings. It offers specialised protection against sulphide-containing environments and aggressive produced fluids in sour service applications.
- Desalination Plants: Use it for pump impellers and valve seats handling concentrated brine. It maintains structural integrity and resists localised corrosion at the elevated temperatures found in desalination processes.
- Steel cladding: Applied as a cavitation-resistant overlay on steel rudders and stern frames. It provides a protective NiAl-bronze barrier that prevents erosion and corrosion on large marine structures.
Storage and Handling of ERCuNiAl Wire and Rods
Store in original sealed packaging at 15–35°C, <60% RH. Clean tarnished rods with acetone and fine abrasive. Protect MIG spools from moisture and reseal after use. Avoid contamination with zinc, lead, or sulphur. No re-baking required. Shelf life is indefinite when stored dry.
Available Forms, Diameters and Packaging of ERCuNiAl
Check the following data for the various wire diameters, spool sizes, and rod lengths available for ERCuNiAl.
| Form | Diameters | Packaging |
|---|---|---|
| MIG Spooled Wire | 0.9, 1.2, 1.6 mm | 12 in spool (30 lb / 13.6 kg) |
| TIG Bare Filler Rod | 1.6, 2.4, 3.2, 4.0, 4.8 mm | 10 lb box, 914 mm (36 in) length |
| TIG Rod (short) | 3.2, 4.0 mm | 10 lb tube, 355 mm (14 in) length |
How to Order ERCuNiAl Nickel-Aluminium Bronze Wire from Nicorex Alloys
When ordering ERCuNiAl from Nicorex Alloys, specify the following 9 details in your RFQ:
- AWS classification: ERCuNiAl per A5.7 (or ECuNiAl per A5.6)
- Product form: MIG spooled wire or TIG bare filler rod
- Diameter (mm or inches)
- Quantity (kg)
- MIL-B-21230 Alloy 1 conformance (if required)
- Classification society approval: DNV, ABS, Lloyds, BV
- Base metal specification: C95800 or equivalent
- Test certificate type: EN 10204 3.1 / 3.2
- Delivery destination: domestic or international
Frequently Asked Questions
What is the Price of ERCuNiAl welding wire per kg in India?
ERCuNiAl is a speciality alloy that costs more than ERCuAl-A2 due to the 4–5.5% nickel content. Pricing varies with diameter, form, and quantity. Contact Nicorex Alloys for a current quotation.
What is the Difference between ERCuNiAl and ERCuMnNiAl?
ERCuNiAl has high nickel (4–5.5%) and matches NiBral C95800 at 718 MPa. ERCuMnNiAl has high manganese (11–14%) and matches MnNiAl castings at 759 MPa. Always check the propeller’s material certificate before selecting a filler.
What is NiBral, and why does it need a Specific Filler Metal?
NiBral stands for Nickel-Bronze-Aluminium and refers to C95800 (ASTM B148). The 4–5% nickel is essential for corrosion performance. A standard filler like ERCuAl-A2 (zero nickel) creates a nickel-depleted weld zone vulnerable to preferential corrosion in seawater.
Is Preheat Required when Welding NiBral with ERCuNiAl?
150–200°C preheat is recommended for sections exceeding 19 mm, with slow cooling. A temper anneal at 675°C for 6 hours may be required per ASTM B148 to restore corrosion resistance.
What is the F-Number of ERCuNiAl per ASME Section IX?
Per ASME Section IX QW-432, this material is classified as F-Number 36, has no assigned A-Number, and follows the SFA-5.7 specification.
What Sizes are Available for ERCuNiAl Spooled Wire and TIG Rods?
MIG wire comes in 0.9, 1.2, and 1.6 mm diameters on 30 lb spools, while TIG rods are 1.6 to 4.8 mm at 914 mm lengths. Use 355-mm 3.2 or 4.0 mm rods for limited propeller blade repairs.
Can ERCuNiAl be used for Overlay on Steel?
Yes. ERCuNiAl produces a 718 MPa cavitation-resistant overlay. The first layer dilutes with iron from the substrate; the second and subsequent layers reach full NiAl bronze properties.
When should ERCuNiAl not be used?
Avoid ERCuNiAl on MnNiAl propeller metals (use ERCuMnNiAl), for soft bearing overlay (196 HBW is too hard; use ERCuAl-A1 at 125 HBW), for general aluminium bronze joining where cost matters (use ERCuAl-A2), and in ammonia environments where copper alloys risk stress corrosion cracking.