AWS Class ENi-Cl Welding Electrodes
AWS A5.15 ENi-Cl Welding Electrode Supplier in Mumbai, India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified importer, stockist, and supplier of ENi-Cl welding electrodes based in Mumbai, India. We provide electrodes classified under AWS A5.15 (ASME SFA 5.15, EN ISO 1071 / EC Ni-Cl 3, UNS W82001),
The weld deposit contains at least 85% nickel (typically 91–99.5%), with a maximum of 8% iron, 2% carbon, 4% silicon, and 2.5% copper. Use this electrode to repair cracked engine blocks, split pump housings, and defective foundry castings made from cast iron. The weld metal has a tensile strength of 40–72 ksi (280–500 MPa), elongation of 3–18%, and a hardness of 150–175 HB. This relatively soft hardness helps absorb contraction stresses and reduces the risk of cracking the brittle cast iron base metal. ENi-Cl electrodes are used for SMAW with AC or DCEP polarity and can be welded in all positions. They are suitable for grey iron, ductile iron, malleable iron, and for dissimilar joints to mild steel, stainless steel, and copper alloys. Standard diameters range from 2.4 mm (3/32″) to 4.8 mm (3/16″), in lengths of 300–350 mm, supplied in hermetically sealed cans and vacuum-packed tubes.
Typical components for repair include engine blocks, pump housings, machine bases, pipe fittings, valve bodies, and gearbox casings. Every batch ships with an MTC 3.1 per EN 10204, a chemical analysis report, and weld metal test results.
ENi-Cl Electrode Specifications
These specifications describe ENi-Cl (Nickel 99) cast iron welding electrodes, detailing their composition, properties, applications, and recommended welding conditions.
| AWS Classification | ENi-Cl |
|---|---|
| AWS Specification | A5.15 (Specification for Welding Electrodes and Rods for Cast Iron) |
| ASME SFA | SFA 5.15 |
| UNS Number | W82001 |
| Welding Process | SMAW (Shielded Metal Arc Welding / Stick Welding / MMA) |
| Electrode Core | Pure Nickel (99% Ni min) |
| Coating Type | Graphite-based / light proprietary coating |
| Polarity / Current | AC or DCEP (DC+, Reverse Polarity) |
| Welding Positions | All – Flat (F), Vertical (V), Overhead (OH), Horizontal (H) |
| Available Diameters | 2.4 mm (3/32″), 3.2 mm (1/8″), 4.0 mm (5/32″), 4.8 mm (3/16″) |
| Electrode Length | 300 mm (12″) for 2.4 mm; 350 mm (14″) for 3.2-4.8 mm |
| ASME Section IX F-Number | F-59 |
| ASME Section IX A-Number | Not assigned (nickel-base deposit) |
| Weld Deposit Type | Soft, fully machinable pure nickel deposit |
| Hardness of Deposit | 150-175 HB (typical) |
| Shielding Gas | Not applicable (SMAW – flux coating provides shielding) |
Understanding the ENi-Cl AWS Classification Breakdown
Each letter in the ENi-Cl designation carries a specific meaning under AWS A5.15, and reading it correctly drives electrode selection.
| Designation Element | Meaning |
|---|---|
| E | Electrode – covered/coated electrode for the SMAW process |
| Ni | Nickel – primary alloying element in the core wire and deposit (99% Ni) |
| C | Cast iron – the intended base metal family |
| l (lowercase L) | Standard type designation within the AWS A5.15 cast iron electrode family |
AWS A5.15 covers ENi-Cl (pure nickel), ENiFe-Cl (nickel-iron), ENiCu-A/B (nickel-copper), ESt (steel), and ECu (copper). ENi-Cl is the premium choice for post-weld machinability. ENiFe-Cl trades machinability for higher tensile strength on heavy sections. ESt costs the least but produces a hard, non-machinable deposit suited only to non-critical repairs.
Weld Deposit Chemical Composition of AWS ENi-Cl (%)
ENi-Cl all-weld-metal chemistry per AWS A5.15, using typical manufacturer data that changes with welding parameters and base metal dilution.
| Element | Nickel (Ni) | Carbon (C) | Iron (Fe) | Silicon (Si) | Manganese (Mn) | Copper (Cu) | Aluminium (Al) | Sulphur (S) | Phosphorus (P) | Other (each) |
|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.15 Limits | ≥85.0% (min) | ≤2.0% | ≤8.0% | ≤4.0% | ≤2.5% | ≤2.5% | ≤1.0% | ≤0.03% | Not specified | ≤1.0% |
| Typical Values | 91.5-99.5% | 0.50-0.85% | 4.0-5.0% | 1.5-1.8% | 0.20-0.30% | 1.0-1.5% | <0.5% | 0.006-0.015% | 0.01-0.02% | – |
High nickel (≥85%) gives the deposit its machinability and thermal expansion match with cast iron. The nickel matrix absorbs carbon from the base metal without forming brittle iron carbides. Higher dilution (wider weave, higher amperage) raises carbon and iron pickup, reducing machinability. Short stringer beads and low heat input keep dilution in check.
Mechanical Properties of ENi-Cl Weld Deposit
Mechanical properties of all-weld metal per AWS A5.15, evaluated in the as-welded state, without any post-weld heat treatment (PWHT).
| Property | Tensile Strength | Yield Strength (0.2%) | Elongation | Hardness | Impact Toughness |
|---|---|---|---|---|---|
| Range / Typical Value | 40-72 ksi (280-500 MPa) | 38-57 ksi (266-393 MPa) | 3-18% | 150-175 HB (Brinell) | Not typically specified per AWS A5.15 for cast iron electrodes |
The wide range reflects dilution and technique. Minimal dilution yields a deposit close to pure nickel with higher ductility. Heavy dilution raises carbon pickup, increasing hardness while cutting ductility. A hardness of 150-175 HB confirms the deposit machines with standard HSS tooling. ENiFe-Cl deposits run 180-220 HB and may need carbide tooling; ESt deposits are generally non-machinable.
Base Metals Welded with ENi-Cl Coated Electrode
ENi-Cl electrodes join and repair the following cast iron grades and dissimilar combinations.
| Joint Type | Materials / Grades | Notes |
|---|---|---|
| Similar Joints | Grey cast iron (ASTM A48, ASTM A126, ASTM A278) | Common cast iron grades |
| Ductile cast iron (ASTM A536) | Also called nodular cast iron | |
| Malleable cast iron (ASTM A47) | Heat-treated cast iron | |
| Compacted graphite iron (CGI) | Used in high-strength cast components | |
| Ni-Resist austenitic cast iron | Test weld recommended | |
| Dissimilar Joints | Cast iron to carbon steel (ASTM A36, ASTM A106, ASTM A516) | Frequently used structural and pressure grades |
| Cast iron to low-alloy steel | Compatible with nickel filler metals | |
| Cast iron to stainless steel (304, 316) | Used in corrosion-resistant assemblies | |
| Cast iron to copper alloys | Requires suitable nickel-based filler metals |
Cast iron falls outside ASME P-Number grouping (QW-422); WPS qualification is per project specification. ENi-Cl performs best on low to moderate phosphorus iron. High-phosphorus iron (>0.3% P) risks phosphide networking; ENiFe-Cl is more tolerant.
Recommended Welding Parameters for ENi-Cl Welding Rod
Use the lowest practical amperage to minimise heat input and dilution from the cast iron base metal.
| Diameter | Voltage (V) | Flat Amps (A) | Vertical/OH Amps (A) |
|---|---|---|---|
| 2.4 mm (3/32″) | 24-28 | 70-85 | 65-75 |
| 3.2 mm (1/8″) | 26-30 | 85-110 | 80-90 |
| 4.0 mm (5/32″) | 28-32 | 110-140 | 100-120 |
| 4.8 mm (3/16″) | 28-32 | 120-160 | 110-130 |
AC polarity delivers the lowest heat input for thin castings and crack-sensitive repairs. DCEP (DC+) gives deeper penetration for fill and cap passes on heavier sections. Thin sections under 12 mm need no preheat. Medium sections (12-25 mm) need 95-175°C (200-350°F). Heavy sections above 25 mm call for 175-300°C (350-570°F). Keep interpass temperature below 175°C (350°F).
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Industrial Applications of ENi-Cl Electrode
ENi-Cl electrodes serve industries where cast iron parts need repair, welding, crack sealing, or section rebuilding with full post-weld machinability.
- Automotive and Engine Repair: Cracked engine blocks, cylinder heads, exhaust manifolds, and transmission housings are standard targets where the finished surface must be machined flat for gasket seating.
- Municipal Water and Sewer Infrastructure: Ageing cast iron water mains, sewer pipes, fire hydrant bodies, and pump station castings require in-situ repair. On-site welding costs far less than full replacement on networks that are 50-100+ years old.
- Foundry and Casting Defect Rectification: Sand holes, porosity, blow holes, cold shuts, and shrinkage cavities in freshly cast parts are filled before machining, salvaging castings that would otherwise be scrapped.
- General Manufacturing and Machine Shops: Cracked machine tool bases, lathe beds, press frames, and gear housings rely on ENi-Cl when repaired surfaces must hold tight dimensional tolerances after machining.
- Mining and Heavy Equipment: Crusher housings, pump casings, and slurry valve bodies benefit from field repair. Cold welding without preheat is useful at remote sites where heating equipment is unavailable.
- Marine and Shipboard Maintenance: Cylinder liners, turbocharger housings, and seawater cooling pump casings are common shipboard repair items. All-position capability and no preheat requirement suit confined engine rooms.
- Power Generation and Utilities: Pump housings, valve bodies, and cooling water system castings at thermal and hydroelectric plants are repaired in situ, avoiding extended outages from full component replacement.
Storage and Handling of ENi-Cl Electrodes
Store in original sealed packaging above 5°C (40°F), relative humidity below 50%, off concrete floors, away from oil and moisture. Rotate first-in, first-out.
Re-dry moisture-affected electrodes at 150°C (300°F) for 1 hour minimum; do not re-dry more than twice. In humid field conditions, use a portable oven at 65-95°C (150-200°F). Once opened, use within 4 hours or transfer to a heated cabinet.
Cast Iron Welding Technique with ENi-Cl Electrode
Cast iron fails under weld-induced thermal stress unless the procedure is controlled at every step.
Joint preparation: Remove all paint, grease, oil, rust, and casting skin by grinding or machining. Bevel cracks deep enough for the first pass to tie into the root. V-groove or U-groove geometry suits through-cracks.
Arc length and bead technique: Hold a short arc of roughly 3 mm (1/8″). Run stringer beads or a narrow weave no wider than 2x electrode diameter. Wide weave patterns cause HAZ cracking.
Intermittent bead length: 25 mm (1″) beads for sections ≤12 mm, 50 mm (2″) for 12-25 mm, and 75-100 mm (3-4″) for sections ≥25 mm.
Peening: Peen each bead while red-hot with a ball-peen hammer to induce compressive stress and relieve tensile shrinkage. This step is not optional.
Cooling and multi-pass: Slow-cool under insulating material (dry sand, lime, vermiculite, or welding blankets). Never quench cast iron. Fill each crater before breaking the arc, and remove all slag before the next pass.
How to Order ENi-Cl (Nickel 99) Electrode from Nicorex Alloys
To place an order for an ENi-Cl (Nickel 99) Electrode, please provide these 10 important details:
- AWS Classification - ENi-Cl per AWS A5.15 / ASME SFA-5.15
- Diameter - 2.4 mm / 3.2 mm / 4.0 mm / 4.8 mm
- Quantity - Specify kg or number of canisters
- Testing / Certification - MTC 3.1/3.2; PMI Report; TPI
- Base Metal - Grey / Ductile / Malleable Cast Iron — specify grade
- Material Grade - Nickel 99; UNS W82001; EN ISO 1071: E C Ni-Cl 1
- Packaging & Certification Scope - Hermetic tin cans / vacuum foil packs; silica gel; ISPM 15 — specify
- Applicable Code - ASME IX; AWS D1.1 — specify
- Delivery - Domestic — specify delivery address
- Remarks - Confirm cast iron grade; cold welding technique — specify repair or fabrication
Nicorex Alloys stocks ENi-Cl and dispatches from Mumbai for fast delivery across India.
Frequently Asked Questions
What is the price of ENi-Cl coated Electrode per kg in India?
ENi-Cl price per kg in India depends on diameter, order quantity, and nickel market rates, so you must contact Nicorex Alloys for a current quotation.
Can an ENi-Cl Electrode be used to weld Cast Iron without Preheating?
Yes, ENi-Cl can cold-weld thin cast iron using AC, the smallest diameter, 25-50 mm stringer beads, and hot peening, while sections over 25 mm need 175-300°C preheat.
What is the difference between ENi-Cl and ENiFe-Cl Cast Iron Electrodes?
ENi-Cl gives a soft, ~99% nickel, 150-175 HB, highly machinable deposit, while ENiFe-Cl gives a stronger Ni-Fe deposit at 180-220 HB that may need carbide tooling.
What types of Cast Iron can be welded with ENi-Cl Electrode?
ENi-Cl welds grey, ductile, malleable, CGI cast irons and joins cast iron to carbon steel, stainless steel, and copper alloys, with test welds advised for Ni-Resist.
When not to use ENi-Cl (Nickel 99) cast Iron Electrode?
Do not use ENi-Cl for ≥50 mm or highly stressed joints, oil-soaked castings without proper degreasing and burn-off, or corrosion/high-temperature service where ENiCrFe-3 or ENiCrMo-3 are preferable.