ER 2553 Welding Wire
- Home
- Welding Consumables
- ER 2553
ER 2553 Welding Wire Supplier in India - AWS A5.9 | UNS S39553
Nicorex Alloys is an ISO 9001 and ISO 14001 certified importer, stockist and supplier of ER2553 super duplex stainless steel welding wire based in Mumbai, India. We supply ER 2553 TIG rods and MIG spools manufactured and tested to AWS A5.9 / ASME SFA-5.9, covering GTAW, GMAW, PAW and SAW processes.
ER2553 (UNS S39553), also referred to as Alloy 2553 filler metal, is among the only AWS-classified super duplex filler wires with an intentional copper addition of 1.5-2.5% Cu. That copper content gives ER2553 weld deposits a distinct advantage in sulphuric acid and reducing-acid service. Its weld metal typically contains about 25% chromium, 5.5% nickel, 3.5% molybdenum, 2% copper and 0.2% nitrogen, forming a balanced mix of ferrite and austenite (30-70 FN). With a PREN of about 40, it is classed as a true super duplex consumable and offers high strength (~745 MPa tensile), good ductility (≥20% elongation), and tough impact performance (≥27 J at −50°C. Nickel is slightly over-alloyed to secure the right phase balance. ER2553 is supplied as TIG rods (1.6-3.2 mm) and MIG wires (0.8-1.6 mm on standard spools) and can be welded in all positions using DCEN for TIG or DCEP for MIG.
Primary base metals include UNS S32520 (Uranus 52N+), S32550 (Ferralium 255), S32750 (SAF 2507) and S32760 (Zeron 100). Core applications span offshore oil and gas platforms, subsea equipment, desalination plants, FGD scrubber systems and chemical processing reactors handling mixed-acid streams. Every spool and rod ships with EN 10204/3.1B mill test certificates, batch test reports, and ferrite number measurement data.
ER 2553 Welding Wire Specifications
The ER2553 specification table below lists the classification, process, dimensions, shielding gas and other details.
| ASME SFA | SFA-5.9 |
|---|---|
| UNS Number | S39553 |
| Welding Processes | GTAW (TIG), GMAW (MIG), SAW, PAW |
| Polarity | (GTAW): DCEN (GMAW): DCEP |
| Welding Positions | All (F, V, H, OH) |
| 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 | 1000 mm |
| Spool Sizes | D200 (5 kg), B300 (15 kg), 25 lb spools |
| Shielding Gas | (GTAW): 100% Argon or Ar + 2–3% N₂ (GMAW): Ar + 2% CO₂ or Ar + 2% O₂ or Ar/He/N₂ tri-mix |
Understanding the ER2553 AWS Classification
The following table clarifies the breakdown of ER2553 welding wire.
| Designator | Meaning | Key Characteristics |
|---|---|---|
| ER | Electrode / Rod | Bare wire used for GMAW or GTAW |
| 2553 | Alloy Family | Super Duplex (25%Cr); “53” denotes copper addition |
Weld Deposit Chemical Composition of ER2553
The chemical composition of ER2553 weld deposits per AWS A5.9 determines its corrosion profile. Copper at 1.5-2.5% is the main feature that sets ER2553 apart from other super duplex fillers.
| Specification | Carbon (C) | Silicon (Si) | Manganese (Mn) | Chromium (Cr) | Nickel (Ni) | Molybdenum (Mo) | Copper (Cu) | Nitrogen (N) | Phosphorus (P) | Sulphur (S) |
|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.9 Req. (%) | 0.04 max | 1.0 max | 1.5 max | 24.0–27.0 | 4.5–6.5 | 2.9–3.9 | 1.5–2.5 | 0.10–0.25 | 0.04 max | 0.03 max |
| Typical (%) | 0.03 | 0.5 | 1.0 | 25.5 | 5.5 | 3.5 | 2.0 | 0.20 | 0.02 | 0.01 |
PREN = %Cr + 3.3(Mo + 0.5W) + 16(%N) = 25.5 + 3.3(3.5) + 16(0.20) = ~40.3. which falls in the super duplex range (PREN > 40). Nickel is kept slightly higher than the base metal (4.5-6.5%) to form enough austenite and achieve 30-70 FN ferrite. Nitrogen (0.10-0.25%) further stabilises austenite and boosts PREN.
All-Weld-Metal Mechanical Properties of ER2553
Mechanical properties of ER2553 all-weld-metal in the as-welded condition are listed below as per AWS A5.9 / ASME SFA-5.9.
| Specification | Tensile Strength | Yield Strength (0.2%) | Elongation | Charpy Impact | Ferrite Number (FN) | Hardness |
|---|---|---|---|---|---|---|
| Typical Value | 745 MPa (108,000 psi) | ~550 MPa (~80 ksi) | ≥20% | ≥27 J at −50°C | 30–70 FN | ~23–28 HRC |
Ferrite content is very important in super duplex welds. Below 25 FN, welds can crack and lose stress corrosion resistance. Above 70 FN, they can become brittle and lose toughness. To control ferrite and austenite balance, adjust heat input and use nitrogen in the shielding gas.
Base Metal Compatibility for ER2553
ER2553 filler wire is matched to copper-bearing super duplex base metals and also serves dissimilar joints.
| Base Metal | UNS | P-No. | ER2553 Use |
|---|---|---|---|
| Uranus 52N+ | S32520 | 10H Gr1 | Similar joint — matching Cu chemistry |
| Ferralium 255 | S32550 | 10H Gr1 | Similar joint — matching Cu chemistry |
| SAF 2507 | S32750 | 10H Gr1 | Can be used; ER2594 may be preferred for Mo match |
| Zeron 100 | S32760 | 10H Gr1 | Can be used where Cu resistance is needed |
| Super duplex castings | ASTM A890 | — | Matching chemistry for cast alloy grades |
| Dissimilar: SD to CS | S32520 to P-1 | — | ER2553 provides an over-alloyed transition |
| Dissimilar: SD to 316L | S32520 to P-8 | — | ER2553 provides intermediate composition |
Recommended Welding Parameters for ER2553
Recommended welding parameters for ER2553 during GTAW and GMAW processes are summarized below to maintain proper ferrite–austenite balance.
GTAW (TIG) Parameters
| Wire Diameter (mm) | Current (A) DCEN | Voltage (V) | Gas Flow (L/min) |
|---|---|---|---|
| 1.6 | 80–130 | 10–14 | 8–12 |
| 2.0 | 100–160 | 10–15 | 8–12 |
| 2.4 | 130–200 | 11–16 | 10–15 |
| 3.2 | 180–280 | 12–18 | 10–15 |
GMAW (MIG) Parameters
| Wire Diameter (mm) | Current (A) DCEP | Voltage (V) | Gas Flow (L/min) |
|---|---|---|---|
| 0.8 | 60–120 | 18–22 | 12–18 |
| 1.0 | 100–180 | 20–26 | 12–18 |
| 1.2 | 140–260 | 22–30 | 15–20 |
| 1.6 | 200–350 | 24–32 | 15–20 |
Control heat input between 0.4-1.2 kJ/mm and cap interpass temperature at 150°C (300°F). Use nitrogen-enriched backing gas (Ar + 2–3% N₂) on the root side to maintain the austenite-ferrite balance. Stringer beads are preferred over weaving for ferrite control.
Premium Industrial Materials
Get ER 2553 Welding Wire at Competitive Prices
ISO Certified
Custom Sizes
Fast Delivery
Industrial Welding Applications of ER2553 MIG Welding Wire
ER2553 copper-bearing super duplex welds are used in three key industries that need both strong chloride resistance and protection from reducing acids.
- Offshore Oil & Gas: Subsea manifolds, flowline tie-ins, subsea Christmas tree components and topside piping on offshore platforms demand weld metal that resists chloride pitting in hot seawater.
- Chemical & Sulphuric Acid Processing: H₂SO₄ concentrators, acid coolers, and reactor vessels use ER2553 MIG Welding Wire to prevent reducing acid-attack.
- Desalination & Water Treatment: Reverse osmosis high-pressure piping, brine heater tubes and multi-stage flash distillation components operate in hot chloride solutions.
Available Forms & Packaging of ER2553
ER2553 welding wire is stocked in 3 product forms that cover GTAW, GMAW, and SAW requirements.
| Form | Diameter Range | Packaging |
|---|---|---|
| TIG Rods (cut lengths) | 1.6–3.2 mm, 1000 mm length | 5 kg tubes |
| MIG Spools | 0.8–1.6 mm | D200 (5 kg), B300 (15 kg), 25 lb spools |
| Core Wire (SAW) | 1.6–6.0 mm | Coils, custom packaging on request |
How to Order ER2553 Welding Wire from Nicorex Alloys
To order ER2553 super duplex welding wire, provide us with the following details for a quotation.
- AWS Classification (ER2553)
- Product Form (TIG rod, MIG spool, core wire)
- Diameter (mm)
- Quantity (kg or number of spools)
- Spool Size (D200, B300, 25 lbs)
- Required Approvals (DNV, ABS, Lloyds, NORSOK)
- Mill Test Certificate (EN 10204/3.1B)
- Ferrite Measurement Requirements
- Delivery Destination (domestic / export)
Matching consumable sets (ER2553 wire + E2553-16 electrode) are available on request for projects requiring multiple process coverage.
Frequently Asked Questions
Why does ER2553 Contain Copper (Cu) while ER2594 does not?
The 1.5–2.5% copper in ER2553 improves resistance to sulphuric and other reducing acids. ER2594 without copper is used for chloride pitting. Use ER2553 for sulphuric acid service and ER2594 for seawater and general chloride conditions.
What ferrite number should ER2553 Weld Deposits achieve?
To get the right balance between strength and corrosion resistance, ER2553 should aim for 30 to 70 FN in the finished weld. Below 25 FN, the weld can hot crack; above 70 FN, it can turn brittle.
Can ER2553 be used to weld SAF 2507 (UNS S32750)?
ER2553 can weld SAF 2507, but ER2594 is usually chosen because its composition, especially molybdenum, better matches 2507.
What is the maximum service temperature for ER2553 Super Duplex Welds?
The maximum recommended continuous service temperature is 250°C (482°F). Above ~300°C, sigma and chi intermetallic phases form, causing embrittlement and loss of corrosion resistance.
What is the difference between ER2553 and ER2209?
ER2209 is the standard duplex filler for welding 2205-type steels. ER2553 is a super duplex filler for 25Cr super duplex steels. Using ER2553 on 2205 over-alloys the weld, while using ER2209 on super duplex steels under-alloys the joint and can reduce corrosion resistance.
When not to use ER2553 Welding Wire?
Do not use ER2553 for standard duplex 2205. Avoid using ER2553 welds for long-term service above 250°C, as sigma phase embrittlement risk increases sharply above 300°C. Keep welding heat input below 1.5 kJ/mm to preserve the duplex ferrite–austenite balance.