AWS Class ERNiCu-7 MIG & TIG
ERNiCu-7 MIG & TIG Filler Metal and Wire Supplier in Mumbai, India
Nicorex Alloys is a Mumbai-based ISO 9001 and ISO 14001 certified stockist and supplier of ERNiCu-7 welding wire, the nickel-copper filler metal classified under AWS A5.14 (ASME SFA 5.14) for GTAW, GMAW, SAW, and PAW welding of Monel 400 and related nickel-copper alloys.
This bare solid wire deposits weld metal with a nominal balance of 65% Nickel, 30% Copper, 3% Manganese, and 2% Titanium. Titanium, at 1.5–3.0%, is the defining metallurgical feature. This material is commonly known as Monel Filler Metal 60 or Alloy 60 (UNS N04060). It acts as a deoxidiser and desulphuriser to control porosity, the primary defect in gas-shielded NiCu welding. ERNiCu-7 TIG rod and MIG wire join Monel 400 (N04400), R-405 (N04405), and K-500 (N05500) to themselves. AWS A5.14 sets a minimum tensile strength of 480 MPa (70 ksi) for the as-welded deposit. The weld zone is not age-hardenable; joining Monel K-500 is softer than the precipitation-hardened base metal. High-quality marine and offshore industries use ERNiCu-7 as the standard for important Monel welds that are free of holes.
Nicorex Alloys supplies ERNiCu-7 MIG & TIG filler metal and wire with MTC 3.1 per EN 10204. Available as TIG filler rod in 1.6 to 3.2 mm diameters and as MIG spool in 0.9 to 1.6 mm, this Monel 400 filler metal serves marine, desalination, chemical processing, oil and gas, and power generation sectors worldwide.
ERNICU 7 Welding Wire Specifications
The specification profile of ERNiCu-7 filler metal and wire, covering standards, process data, and packaging, is listed below.
| UNS Designation | N04060 |
|---|---|
| Welding Processes | GTAW (TIG), GMAW (MIG), SAW, PAW |
| Polarity | GTAW: DCEN | GMAW: DCEP |
| Welding Positions | All positions |
| Shielding Gas | GTAW: 100% Argon GMAW: 75% Ar / 25% He, 90% He / 7.5% Ar / 2.5% CO₂, 69% Ar / 30% He / 1% CO₂ |
| TIG Rod Diameters | 1.6, 2.0, 2.4, 3.2 mm |
| MIG Wire Diameters | 0.8, 0.9, 1.0, 1.2, 1.6 mm |
| TIG Rod Length | 900–1000 mm |
| TIG Packaging | 5 kg tubes, 20 kg cartons |
| MIG Spool | 15 kg (D300) |
| SAW Coil | 25 kg |
What Does the AWS Classification ERNiCu-7 Mean?
The AWS designation ERNiCu-7 breaks down as follows. Each segment identifies a specific characteristic of the filler metal per AWS A5.14.
| Designation Segment | Meaning |
|---|---|
| ER | Electrode/Rod: bare solid wire or rod for GTAW, GMAW, SAW, PAW |
| Ni | Primary element is Nickel (62-69%) |
| Cu | Secondary element is Copper (remainder, approx. 28-34%) |
| 7 | Seventh composition variant in the NiCu family within AWS A5.14 |
ERNiCu-7 (UNS N04060) is not the same composition as Monel 400 base metal (UNS N04400). The filler metal has more titanium (1.5-3.0% vs trace in base metal) and manganese (up to 4.0%) to reduce porosity. AWS A5.11-compliant SMAW electrode is ENiCu-7.
Weld Deposit Chemical Composition of ERNiCu-7
Chemical composition requirements for the ERNiCu-7 weld deposit, per AWS A5.14, are listed below.
The chemical composition of ERNiCrMo-13 Welding Wire, as per AWS A 5.14, along with its proportion, is listed below in the table:
| Element | Nickel (Ni) | Copper (Cu) | Titanium (Ti) | Manganese (Mn) | Iron (Fe) | Silicon (Si) | Aluminium (Al) | Carbon (C) | Phosphorus (P) | Sulphur (S) | Other Elements, Total |
|---|---|---|---|---|---|---|---|---|---|---|---|
| Composition (wt%) | 62.0–69.0 | Remainder | 1.5–3.0 | 4.0 max | 2.5 max | 1.25 max | 1.25 max | 0.15 max | 0.020 max | 0.015 max | 0.50 max |
These numbers represent weld deposit analysis. Base metal dilution, pass count, and process factors affect chemistry. Titanium at 1.5-3.0% creates stable TiO₂ and TiS compounds, forming sound, porosity-free deposits in slag.
All-Weld-Metal Mechanical Properties of ERNiCu-7
Mechanical properties of the ERNiCu-7 weld deposit include AWS A5.14 minimum requirements and typical as-welded.
| Property | Tensile Strength (AWS min) | Tensile Strength (Typical) | Yield Strength, 0.2% Offset (Typical) | Elongation (AWS min) | Elongation (Typical) |
|---|---|---|---|---|---|
| Value | 480 MPa (70 ksi) | 517 MPa (75 ksi) | 358 MPa (52 ksi) | 30% | 34% |
The weld deposit is solid-solution reinforced, not age-hardenable. Gamma-prime precipitation hardening hardens Monel K-500 base metal to 1000+ MPa, whereas the ERNiCu-7 weld zone stays at 517 MPa.
Base Metal Compatibility and P-Number Matrix for ERNiCu-7
ERNiCu-7 Monel 400 TIG filler rod and MIG wire are qualified for joining the following base metals. ASME Section IX classifies ERNiCu-7 as F-42 per QW-432 (A-Number: not applicable, as it is a non-ferrous filler).
Similar metal joints:
| Base Metal | P-Number | ASTM Specs |
|---|---|---|
| Monel 400 (N04400) | P-42 | B127, B163, B164, B165 |
| Monel R-405 (N04405) | P-42 | B164 |
| Monel K-500 (N05500) | P-42 | B865 |
Dissimilar metal joints:
| Combination | Classification / Note |
|---|---|
| Nickel 200/201 (N02200/N02201) | P-41 to P-42 |
| CuNi 70/30 (C71500) | P-34 to P-42 |
| CuNi 90/10 (C70600) | P-34 to P-42 |
| Carbon Steel (P-1) to Monel 400 (P-42) | ERNi-1 buffer layer required |
When overlaying ERNiCu-7 on carbon steel, apply a buffer layer of ERNi-1 (pure nickel, F-41) as the first pass. Direct deposition of NiCu weld metal on steel causes iron dilution that degrades corrosion resistance and can trigger hot cracking at the fusion line.
Recommended Welding Parameters for ERNiCu 7 Tig Rod
The table below shows important welding parameters for ERNiCu-7, such as the maximum interpass temperature and the steps for cleaning the surface.
GTAW (TIG) parameters:
| Joint Thickness | Tungsten Dia. | Filler Dia. | Amps (A) | Volts (V) | Gas |
|---|---|---|---|---|---|
| 0.75-1.6 mm | 1.6 mm | 1.6 mm | 35-60 | 9-12 | 100% Ar |
| 1.6-3.2 mm | 1.6-2.4 mm | 1.6-2.4 mm | 50-95 | 9-12 | 100% Ar |
| 3.2-6.4 mm | 2.4-3.2 mm | 2.4-3.2 mm | 75-150 | 10-13 | 100% Ar |
| 6.4 mm+ | 2.4-3.2 mm | 2.4-3.2 mm | 95-200 | 10-13 | 100% Ar |
GMAW (MIG) short-circuiting parameters:
| Wire Dia. | Amps (A) | Volts (V) | Wire Speed (ipm) | Gas |
|---|---|---|---|---|
| 0.9 mm | 70-90 | 18-20 | 150-200 | 75Ar/25He |
| 1.2 mm | 75-160 | 19-22 | 175-225 | 75Ar/25He |
Use 1.2 mm wire at 190–250 A and 30–32 V with 100% Argon shielding for GMAW spray transfer. To get the best results with SAW, use 2.4 mm wire at 275–350 A or 3.2 mm wire at 350-450 A with a suitable flux.
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Industrial Applications of ERNICU 7 Filler Wire
The following are the industrial applications of ERNiCu-7 filler wire:
- Marine and offshore: Seawater piping, shipboard heat exchangers, propeller shafts, pump casings, and hull fittings fabricated from Monel 400 in naval and commercial vessels.
- Desalination: MSF evaporator tubes, brine heater tube-to-tubesheet joints, and piping in thermal desalination plants exposed to hot brine.
- Chemical processing (HF acid service): Hydrofluoric acid alkylation units, HF storage vessels, and reaction columns where Monel 400 is the standard material of construction.
- Oil and gas: Sour gas production tubing, downhole components, and subsea valves exposed to H₂S and CO₂ with chlorides.
- Salt production: Evaporator bodies, crystalliser vessels, and brine handling piping.
- Pulp and paper: Bleach plant piping and chlorine handling systems.
- Power generation: Feedwater heater tubing, condensate piping, and deaerator internals in fossil and nuclear plants.
- Cladding and overlay: Weld overlay of carbon steel vessels with ERNiCu-7 MIG wire (after ERNi-1 buffer layer) for a corrosion-resistant NiCu surface at lower cost than solid Monel.
Storage and Handling of ERNiCu-7 Welding Filler Wire
ERNiCu-7 is a bare solid wire, so the storage concern is surface contamination rather than moisture absorption. Spools and rods should be stored in their original packaging at 15-30 °C with humidity below 60% RH. Avoid carbon steel tools and grinding dust. Even trace iron on the wire surface reduces the NiCu weld deposit’s corrosion resistance. Clean TIG rods with acetone first. After each shift, seal partially used MIG spools.
Available Forms, Diameters and Packaging of ERNiCu-7 Wire
ERNiCu-7 MIG & TIG filler metal and wire from Nicorex Alloys is stocked in the following forms.
| Form | Diameter | Packaging |
|---|---|---|
| TIG Rod (GTAW) | 1.6, 2.0, 2.4, 3.2, 4.0 mm | 5 kg tubes, 20 kg cartons |
| MIG Spool (GMAW) | 0.8, 0.9, 1.0, 1.2, 1.6 mm | 15 kg spool (D300) |
| SAW Wire | 2.4, 3.2 mm | 25 kg coils |
| Strip (Cladding) | Available on request | Per order |
All shipments carry Mill Test Certificate 3.1 per EN 10204 with full heat and lot traceability.
How to Order ERNiCu-7 MIG & TIG Filler Metal from Nicorex Alloys
To get a quotation for ERNiCu-7 Monel 400 welding wire, share these 8 details:
- AWS Classification - ERNiCu-7 per AWS A5.14
- Product Form - TIG Rod / MIG Spool / SAW Wire
- Diameter - Specify in mm
- Quantity - In kg
- Spool Type & Size - Specify
- Third-Party Approvals - ABS / DNV / Lloyds / Bureau Veritas / TÜV
- Test Certificate - MTC 3.1 per EN 10204
- Delivery Destination - Specify
As a distributor, Nicorex Alloys supplies matching consumables across processes: ERNiCu-7 TIG rod, MIG wire, and ENiCu-7 SMAW electrode for the same Monel 400 project.
Frequently Asked Questions
What is the Price of ERNiCu-7 Welding Wire per kg in India?
ERNiCu-7 is priced at ₹2,000–₹3,500 per kilogram in this location. Total costs change based on MIG/TIG formats and diameter. Any additional third-party certifications will also influence the per-kg rate. Contact Nicorex Alloys with your diameter and quantity for a quotation.
Why is a Buffer Layer of ERNi-1 Required Before Overlaying ERNiCu-7 on Carbon Steel?
Direct deposition of ERNiCu-7 on carbon steel draws excessive iron into the NiCu weld deposit. Iron above roughly 5% degrades corrosion resistance in seawater and acid service. The Fe-Ni-Cu system can generate a brittle intermetallic at the fusion border, triggering hot cracking. A pure nickel ERNi-1 buffer layer protects the overlay from iron pickup.
Can ERNiCu-7 Filler Wire Achieve the Same Strength as Monel K-500 Base Metal?
No. ERNiCu-7 weld metal exhibits strong solution strengthening but little age hardening. However, gamma primary precipitation hardening gives the Monel K-500 alloy yield strengths over 1000 MPa, while the ERNiCu-7 weld metal has only 517 MPa. This must be considered in K-500 weld structural design.
What is the Role of Titanium in the ERNiCu-7 Filler Metal Composition?
Titanium (1.5-3.0% per AWS A5.14) acts as a deoxidiser and desulphuriser. The NiCu alloy system is highly prone to porosity from dissolved oxygen and sulphur. Titanium creates sound deposits in slag by forming stable TiO₂ and TiS compounds that float.
What is the Difference Between ERNiCu-7 and ERCuNi for Welding Copper-Nickel Alloys?
Monel 400 uses ERNiCu-7 (AWS A5.14), a nickel-base filler with 65% Ni and 30% Cu. ERCuNi (AWS A5.7) is a copper-base filler for 70/30 and 90/10 CuNi alloys with 70% Cu and 30% Ni.
When Should ERNiCu-7 Not Be Used?
Don’t use ERNiCu-7 at 480-540°C. It has no chromium, so it oxidises fast. Avoid using it for Monel K-500 weld strength.
What Shielding Gas is Recommended for GMAW with ERNiCu-7 MIG Wire?
For short-circuiting transfer, the standard recommendation is 75% Ar / 25% He. Alternatives include 90He/7.5Ar/2.5CO₂ and 69Ar/30He/1CO₂ trimix. For spray transfer on 10 mm+ portions, use 100% argon.