AWS Class E2209T1-1/T1-4 Flux Core
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E2209T1-1/T1-4 Duplex Stainless Steel Flux Core Wire Supplier in India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified importer, stockist, and supplier of E2209T1-1/T1-4 duplex stainless steel flux cored wire based in Mumbai, India. These wires are classified under AWS A5.22 / ASME SFA-5.22.
The E2209T1 is a rutile-type FCAW electrode that delivers 2-3× the deposition rate of conventional SMAW electrodes and runs in all positions on DCEP polarity, making it a reliable consumable for high-productivity duplex fabrication. The wire deposits an over-alloyed weld metal containing approximately 22.5% Cr, 9% Ni, 3.2% Mo, and 0.13% N. That deliberate nickel surplus promotes austenite formation and restores the critical dual-phase microstructure in the as-welded condition. The duplex 2209 FCAW wire produces a balanced austenite-ferrite deposit with 25-55 FN ferrite number and a PREN above 35, giving each weld resistance to pitting and chloride stress corrosion cracking. Tensile strength meets 690 MPa (100 ksi) minimum, yield strength exceeds 450 MPa (65 ksi), and Charpy impact is tested at −46°C. Available diameters are 0.9, 1.0, 1.2 mm (0.045″), and 1.6 mm (1/16″) on 12.5 kg and 15 kg spools. Shielding gas options include 75-85% Ar / 15-25% CO₂ or 100% CO₂.
Primary base metals are UNS S31803 and S32205 (P-10H Gr.1), S32304, and S32101, plus dissimilar joints to carbon steel (P-1) and austenitic stainless (P-8). Compliance covers AWS A5.22, EN ISO 17633, and NACE MR0175 / ISO 15156. Industries span offshore oil and gas, chemical processing, shipbuilding, pulp and paper, desalination, and fertiliser production. Every spool is batch-tested and ships with an MTC 3.1 per EN 10204.
E2209T1-1/T1-4 Flux Cored Wire Specifications
The specifications of E2209T1-1/T1-4 duplex stainless steel flux cored wire, along with its UNS number, polarity and shielding gas, are listed below:
| AWS Classification | E2209T1-1/T1-4 |
|---|---|
| UNS Number | W39239 |
| Welding Process | FCAW-G (Flux-Cored Arc Welding: Gas Shielded) |
| Flux Core Type | Rutile (fast-freezing slag, good positional control) |
| Polarity | DCEP (DC Electrode Positive) |
| Welding Positions | All positions: F, H, V-up, OH (1G, 2G, 3G, 4G) |
| Shielding Gas | 75-85% Ar / 15-25% CO₂ (recommended) or 100% CO₂ |
| Gas Flow Rate | 20-25 l/min (40-50 CFH) |
| Available Diameters | 0.9, 1.0, 1.2 mm (0.045″), 1.6 mm (1/16″) |
| Spool Sizes | 12.5 kg (28 lb), 15 kg (33 lb) on D200 and D300 |
AWS Classification E2209T1-1/T1-4 Explained
The AWS A5.22 classification E2209T1-1/T1-4 is decoded as follows in the table below:
| Designator | Meaning |
|---|---|
| E | Electrode: a consumable electrode that conducts current |
| 2209 | Weld deposit chemistry: 22% Cr, 9% Ni duplex type |
| T | Tubular electrode (flux cored wire construction) |
| 1 | Welding position: 1 = all-position (F, H, V-up, OH) |
| – (dash) | Separator |
| 1 | Shielding gas: 100% CO₂ OR Ar/CO₂ mixed gas |
| /T1-4 | Dual classification: 4 = Ar/CO₂ mix only |
The dual designation means this wire meets AWS requirements with both 100% CO₂ and Ar/CO₂ mixed gas. A T1-4-only wire has been tested with Ar/CO₂ alone. Buyers should note the T0 variant: E2209T0-1/T0-4 covers flat and horizontal positions only, so T1 must be specified for vertical-up and overhead work.
Weld Deposit Chemical Composition of E2209T1-1/T1-4
The all-weld-metal chemical composition of E2209T1-1/T1-4 flux cored wire, as per AWS A5.22, is given below.
| Material / Element | Carbon (C) | Manganese (Mn) | Silicon (Si) | Chromium (Cr) | Nickel (Ni) | Molybdenum (Mo) | Nitrogen (N) | Phosphorus (P) | Sulphur (S) | Copper (Cu) |
|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.22 Requirement | 0.04 max | 0.50-2.00 | 1.00 max | 21.0-24.0 | 7.50-10.0 | 2.50-4.00 | 0.08-0.20 | 0.04 max | 0.03 max | 0.75 max |
| Typical (Ar/CO₂) | 0.025-0.030 | 0.9-1.1 | 0.6-0.8 | 22.5-23.0 | 8.8-9.2 | 3.0-3.3 | 0.10-0.14 | 0.020-0.033 | 0.001-0.010 | 0.01-0.10 |
These are weld deposit values (all-weld-metal analysis), not wire analysis. Nickel is over-alloyed at 8.8-9.2% versus ~5.5% in 2205 base metal to promote austenite and avoid excessive ferrite. Nitrogen (0.08-0.20%) is the strongest austenite stabiliser and a major contributor to pitting resistance. Calculated PREN (%Cr + 3.3×%Mo + 16×%N) reaches approximately 35.6, above the 34 threshold for duplex service.
All-Weld-Metal Mechanical Properties of E2209T1-1/T1-4
The all-weld-metal mechanical properties of E2209T1-1/T1-4 duplex flux cored wire as per AWS A5.22 are given below.
| Property | Tensile Strength (Rm) | Yield Strength (Rp0.2) | Elongation (A, Lo=5d0) | Hardness |
|---|---|---|---|---|
| AWS A5.22 Minimum | ≥ 690 MPa (100 ksi) | ≥ 450 MPa (65 ksi) | ≥ 20% | Not specified |
| Typical (Ar/CO₂) | 780-830 MPa (113-120 ksi) | 550-620 MPa (80-90 ksi) | 25-32% | 230-260 HB |
Base Metal Compatibility and P-Number Matrix for E2209T1-1/T1-4
E2209T1-1/T1-4 flux cored wire is qualified to join the following base metals, identified by their ASME Section IX P-Numbers.
Similar Metal Joints:
| Base Metal | UNS | P-No./Gr. | Joint Type |
|---|---|---|---|
| Duplex 2205 | S32205 | P-10H, Gr.1 | P-10H to P-10H |
| Duplex 2205 (older) | S31803 | P-10H, Gr.1 | P-10H to P-10H |
| Lean Duplex 2304 | S32304 | P-10H, Gr.1 | P-10H to P-10H |
| Lean Duplex 2101 | S32101 | P-10H, Gr.1 | P-10H to P-10H |
Dissimilar Metal Joints:
| Joint Combination | P-Numbers | Notes |
|---|---|---|
| Duplex 2205 to Carbon Steel | P-10H to P-1 | Dilution control critical; use stringer beads |
| Duplex 2205 to 316L SS | P-10H to P-8 | Duplex-austenitic transition weld |
| Duplex 2205 to 304L SS | P-10H to P-8 | Monitor ferrite in the mixed zone |
For dissimilar joints to carbon steel, dilution reduces Cr, Mo, and Ni in the weld zone and can lower PREN below 30. Limit dilution to ≤30% from the carbon steel side and run the first pass with GTAW (ER2209) where possible.
Recommended Welding Parameters for E2209T1-1/T1-4
The table below explains recommended welding parameters for E2209T1-1 and E2209T1-4 duplex flux-cored wires across common diameters and welding positions.
| Diameter | Position | Ampere (A) | Voltage (V) | Shielding Gas |
|---|---|---|---|---|
| 0.9 mm (0.035”) | Flat / Horizontal / Vertical-Up | 100–180 | 22–28 | 75–85% Ar / 15–25% CO₂ |
| 1.2 mm (0.045”) | Flat / Horizontal / Vertical-Up | 130–280 | 23–30 | 75–85% Ar / 15–25% CO₂ |
| 1.6 mm (1/16”) | Flat / Horizontal | 180–350 | 24–32 | 75–85% Ar / 15–25% CO₂ |
Direct current electrode positive (DCEP) polarity is recommended. Gas flow typically ranges from 20 to 25 l/min. Maintain a contact tip-to-work distance of 15–20 mm and keep heat input between 0.5–2.5 kJ/mm to preserve duplex phase balance and corrosion resistance. Preheating is normally unnecessary.
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Industrial Welding Applications of E2209T1-1/T1-4 Duplex Flux Cored Wire
E2209T1-1/T1-4 is specified across industries needing high-productivity FCAW of 22Cr duplex stainless steel.
- Offshore Oil and Gas: Duplex piping (on platforms and subsea), structural parts, manifolds, and FPSO topsides.
- Chemical and Petrochemical Processing: Reactor vessels, heat exchangers, and chemical storage tanks.
- Shipbuilding and Marine: Cargo tanks on chemical tankers, ballast water piping, and seawater cooling lines.
- Pulp and Paper Industry: Bleach plant equipment, digester vessel cladding, and white liquor piping.
- Desalination and Water Treatment: Reverse osmosis pressure vessels, high-pressure pump housings, and brine piping in warm, high-chloride environments.
- Fertiliser and Urea Production: Urea strippers, carbamate condenser tubesheet welds, and ammonia storage vessels.
Storage, Handling and Moisture Control for E2209T1-1/T1-4
Store spools in original sealed packaging at 15-25°C and below 60% relative humidity. Keep spools elevated on pallets or shelving. Once the vacuum seal is broken, use the spool within 24-72 hours or transfer it to a heated wire cabinet at 40-60°C.
If moisture pickup is suspected, re-dry at 130-150°C for 2-4 hours (maximum two re-drying cycles; do not exceed 200°C). Moisture creates hydrogen during welding, which can cause porosity, wormholes, and hydrogen cracking in the ferrite. Always handle spools with clean, dry gloves to avoid contaminating the wire surface.
How to Order E2209T1-1/T1-4 Flux Cored Wire from Nicorex Alloys
To order E2209T1-1/T1-4 Flux Cored Wire, follow these 9 important steps:
- AWS Classification: E2209T1-1/T1-4 (specify T1-1, T1-4, or dual)
- Wire Diameter: 0.9, 1.0, 1.2, or 1.6 mm
- Quantity: in kg, number of spools, or lot size
- Spool Size: 12.5 kg or 15 kg (D200 or D300)
- Shielding Gas: Ar/CO₂ only or dual CO₂ + Ar/CO₂
- Approvals: DNV GL, ABS, Lloyds Register, BV, CWB, TÜV
- Test Certificate: MTC 3.1 per EN 10204 (standard)
- Packaging: Vacuum-sealed standard
- Delivery Destination: Domestic (India)
Nicorex Alloys supplies matching consumables across all processes: E2209-16/17 (SMAW) + ER2209 (TIG/MIG) + E2209T1-1/T1-4 (FCAW) as a complete duplex consumable set.
Frequently Asked Questions
What is the difference between E2209T1-1 and E2209T1-4 Shielding Gas Classifications?
E2209T1-1 can be used with either 100% CO₂ or an Ar/CO₂ gas mix. E2209T1-4 is only approved for Ar/CO₂, and an argon + 20–25% CO₂ mix is recommended to reduce spatter and keep ferrite levels balanced.
How is Ferrite Content controlled in E2209T1-1/T1-4 Weld Deposits?
Ferrite is controlled by nickel over-alloying (8.5-9.5% Ni), keeping heat input within range, and limiting interpass temperature to maintain 25-55 FN.
What are the advantages of E2209T1 FCAW over E2209-16 SMAW for Duplex Welding?
E2209T1 FCAW gives 2–3 times higher deposition, uses a continuous wire feed so you do not have to stop for electrode changes, and comes in vacuum‑sealed low‑hydrogen spools. However, it does require shielding gas.
Can E2209T1-1/T1-4 be used for Root Pass Welding of Duplex Pipe?
No, roots are usually welded with ER2209 GTAW (with argon + 2% N₂ purge), then E2209T1 is used for fill and cap
Why is heat input control critical when welding Duplex with E2209T1-1/T1-4?
Heat input should be kept in the range of about 0.5–2.5 kJ/mm (ideally 0.8–1.8 kJ/mm). If it’s too low, ferrite becomes excessive; if it’s too high, harmful sigma and chi phases can form.
What is the price of E2209T1-1/T1-4 Duplex Flux Cored Wire per kg in India?
The price of E2209T1-1/T1-4 Duplex flux cored wire depends on diameter, spool size, approvals, and quantity. Flux-cored wire costs more than ER2209 solid wire. Contact Nicorex Alloys for a quotation and current stock in Mumbai.