AWS Class ERNi-1 MIG & TIG

ERNi-1 MIG & TIG Filler Metal and Wire Supplier in Mumbai, India

Name: AWS Class ERNi-1 MIG & TIG
Brand: Nicorex Alloys

Nicorex Alloys is an ISO 9001 and ISO 14001 certified Mumbai-based importer, stockist, and supplier of ERNi-1 welding wire and TIG filler rod. We provide these filler metals and wires as classified under AWS A5.14 (ASME SFA 5.14).

Also recognised as Nickel filler metal 61 or Alloy 61, ERNi-1 consumable carries the highest nickel content of any wire in the AWS A5.14 classification (93.0% Ni minimum) in the deposited weld metal. The nominal composition of 93% Ni and 2-3.5% Ti makes ERNi-1 a commercially pure nickel filler metal. Titanium acts as a deoxidiser and desulphuriser to control weld porosity, and reacts with carbon to form stable TiC, keeping free carbon low for compatibility with Nickel 201 (0.02% C max). The weld deposit is deliberately soft at approximately 120–150 HB and fully machinable, making ERNi-1 the preferred filler for cast iron repair. In caustic soda (NaOH) service, the pure nickel deposit is immune to chloride stress-corrosion cracking.

ERNi-1 TIG filler rod is stocked in diameters ranging from 1.6, 2.0, 2.4, 3.2, and 4.0 mm. ERNi-1 MIG wire is stocked in 0.9, 1.0, 1.2, and 1.6 mm spools. Base metals covered include Nickel 200/201 (ASTM B160, B161, B162, B163), carbon steel, stainless steel, INCONEL, Incoloy, Monel, and CuNi alloys. Key industries span Monel/CuNi overlay cladding, caustic soda production, chlor-alkali, cast iron repair, food processing, and nuclear. All shipments carry EN 10204/3.1B mill test certificates.

ERNi-1 Welding Wire Specifications

ERNi-1 filler wire specifications, including classification, polarity, welding positions, diameters, and other important details are covered in the table below:

AWS Classification	ERNi-1
ASME SFA	5.14
UNS Designation	N02061
Welding Processes	GTAW (TIG), GMAW (MIG), SAW, PAW
Polarity	GTAW- DCEN GMAW- DCEP
Welding Positions	All (Flat, Horizontal, Vertical-Up, Vertical-Down, Overhead)
Shielding Gas	GTAW- 100% Argon GMAW- 100% Argon or 75% Ar / 25% He
SAW Flux	INCOFLUX 6
TIG Rod Diameters	1.6, 2.0, 2.4, 3.2, 4.0 mm
MIG Wire Diameters	0.9, 1.0, 1.2, 1.6 mm
TIG Rod Length	915 mm (36″) or 1000 mm (39″)
Packaging	TIG: 5 kg tubes; MIG: 15 kg spools; SAW: 25 kg coils
PWHT	Not required

AWS Classification Explained: What Does ERNi-1 Mean?

The ERNi-1 designation breaks down letter by letter under AWS A5.14.

Designator	Meaning
ER	Electrode/Rod: bare solid wire for GTAW, GMAW, SAW, and PAW
Ni	Primary element is Nickel (93.0% minimum: highest Ni of any AWS A5.14 filler)
1	First composition variant in the pure-nickel family

ERNi-1 (AWS A5.14) is the bare wire form. ENi-1 (AWS A5.11) is the matching SMAW coated electrode. ENi-Cl (AWS A5.15) is a separate nickel electrode for cast iron. ERNiCu-7 (AWS A5.14) is a nickel-copper filler for Monel 400 and is not a substitute for ERNi-1 as a buffer layer. ERNi-1 (UNS N02061) differs from Nickel 200 base metal (UNS N02200). The filler contains 2.0–3.5% titanium, which the base metal does not.

Weld Deposit Chemical Composition of ERNi-1

Weld deposit chemistry per AWS A5.14 is given below. Actual weld chemistry depends on dilution, pass count, and welding parameters.

Element	Nickel (Ni) incl. Co	Titanium (Ti)	Carbon (C)	Manganese (Mn)	Iron (Fe)	Copper (Cu)	Silicon (Si)	Aluminium (Al)	Phosphorus (P)	Sulphur (S)	Other elements (total)
Composition (%)	93.0 min	2.0–3.5	0.15 max	1.0 max	1.0 max	0.25 max	0.75 max	1.50 max	0.03 max	0.015 max	0.50 max

Ni at 93.0% minimum makes this the purest nickel filler in AWS A5.14. Fe at 1.0% max is critical for buffer layer work. Low Cu (0.25% max) separates ERNi-1 from ERNiCu-7, which carries roughly 30% Cu.

All-Weld-Metal Mechanical Properties of ERNi-1

Minimum as-welded mechanical properties, including tensile and yield strength, and elongation, are listed in the table below:

Property	Tensile Strength (min)	Yield Strength, 0.2% Offset (min)	Elongation (min)
Value	414 MPa (60,000 psi)	241 MPa (35,000 psi)	20%

The pure nickel deposit is soft and ductile by design. Hardness at approximately 120–150 HB means ERNi-1 deposits are fully machinable. This is essential for cast iron repair. In buffer layer applications, the soft interlayer accommodates differential thermal expansion between steel and the NiCu or CuNi overlay.

Base Metal Compatibility and P-Number Matrix for ERNi-1

ERNi-1 has the widest dissimilar metal joining range of any pure metal filler, classified under F-Number 41 (SFA 5.14) per ASME Section IX.

Base Metal Group	Typical Materials	ASME P-Number	Compatible Welding with ERNi-1	Typical Application
Pure Nickel Alloys	Nickel 200, Nickel 201	P 41	Similar metal welding	Chemical processing equipment, caustic service
Carbon Steels	Carbon steel piping and pressure vessel steels	P 1	Dissimilar welding to nickel alloys	Nickel equipment connected to carbon steel piping
Low Alloy Steels	Cr, Mo, and other low-alloy steels	P 3, P 4, P 5	Dissimilar welding	Transition joints in refinery and power plants
Austenitic Stainless Steels	304, 304L, 316, 316L	P 8	Dissimilar welding	Nickel alloy to stainless steel connections
Nickel Copper Alloys	Monel 400	P 42	Similar and dissimilar welding	Marine and chemical plant equipment
Nickel Chromium Alloys	INCONEL alloys	P 43	Dissimilar welding	High-temperature process equipment
Nickel Iron-Chromium Alloys	INCOLOY alloys	P 45	Dissimilar welding	Heat-resistant alloy systems
Copper Nickel Alloys	Cu Ni 70/30, Cu Ni 90/10	P 34	Dissimilar welding	Marine piping and desalination plants
Cast Iron Materials	Grey, ductile, malleable cast iron	—	Repair welding	Crack repair and restoration

Recommended Welding Parameters for ERNi-1 Filler Wire

The pure nickel weld pool is sluggish and viscous. The table below lists the recommended welding parameters for ERNi-1 filler wire.

GTAW (TIG) Parameters:

Diameter	Amperage (A)	Voltage (V)	Shielding Gas
1.6 mm (1/16″)	35–80	9–12	100% Argon
2.4 mm (3/32″)	60–130	10–13	100% Argon
3.2 mm (1/8″)	100–180	10–14	100% Argon

GMAW (MIG) Parameters:

Diameter	Amperage (A)	Voltage (V)	Shielding Gas
0.9 mm – Short Circuit	70–90	18–20	75% Ar / 25% He
1.2 mm – Short Circuit	75–160	19–22	75% Ar / 25% He
1.2 mm – Spray Transfer	180–240	28–32	100% Argon

For cast iron, use low amperage, short stringer beads (50 mm max), and peen each bead while hot. Interpass temperature must not exceed 150°C. Joint cleanliness is critical. Nickel is sensitive to sulphur, lead, zinc, and phosphorus contamination.

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Industrial Welding Applications of ERNi-1 Welding Filler Wire

ERNi-1 pure nickel welding wire serves 8 major application areas.

Buffer/barrier layer for overlay cladding: first pass before ERNiCu-7 (Monel 400) or ERCuNi (CuNi 70/30) on carbon steel in marine, desalination, and chemical vessel fabrication.
Caustic soda (NaOH) production: evaporators, concentrators, and piping handling hot concentrated sodium hydroxide.
Chlor-alkali industry: membrane and diaphragm electrolysis cell components and brine handling.
Cast iron welding and repair: grey, ductile, and malleable iron castings, including engine blocks and pump housings.
Food and beverage processing: vessels and piping for fatty acids and alkaline cleaning solutions.
Nuclear: fuel reprocessing equipment and dissimilar joints in reactor systems.
Dissimilar metal joining: transition joints between Nickel 200/201 and SS, CS, Inconel, Incoloy, and Monel alloys.
Surfacing and overlay: pure nickel overlay on carbon steel for caustic, alkaline, and fluorine-containing environments.

Storage and Handling of ERNi-1 TIG Rod

ERNi-1 is a solid bare wire. Thus, moisture absorption is not a concern. Surface contamination is the primary risk. Store in original sealed packaging at 15–30°C, below 60% RH. Keep wire away from sulphur, lead, zinc, and phosphorus. Even trace amounts cause hot cracking in pure nickel welds. Handle with clean gloves and use stainless steel or nickel-dedicated tools only. Before welding, degrease all surfaces with acetone within 25 mm of the joint.

Available Forms, Diameters and Packaging of ERNi-1 Wire

Nicorex Alloys stocks ERNi-1 in the following forms and diameters, with multiple packing options available.

Form	Diameters	Packaging
TIG Rod (GTAW)	1.6, 2.0, 2.4, 3.2, 4.0 mm	915/1000 mm tubes, 5 kg packs
MIG Wire (GMAW)	0.9, 1.0, 1.2, 1.6 mm	15 kg spools
SAW Wire	2.4, 3.2 mm	25 kg coils
SMAW Electrode (ENi-1)	2.4, 3.2, 4.0 mm	Hermetically sealed cans, 2.5/5 kg

All ERNi-1 MIG & TIG filler metal and wire from Nicorex Alloys is supplied with a Mill Test Certificate 3.1 per EN 10204.

How to Order ERNi-1 MIG & TIG Filler Metal & Wire from Nicorex Alloys

When ordering ERNi-1 welding consumables, provide the following details:

AWS Classification - ERNi-1 per AWS A5.14
Product Form - TIG Rod / MIG Spool / SAW Wire
Diameter(s) - Specify required sizes
Quantity - In kg
Packaging Preference - Tubes / Spools
Third-Party Approvals - ABS / DNV / Lloyds / Bureau Veritas / TUV
Test Certificate Requirement - MTC 3.1 per EN 10204
Matching Consumables - Specify if ENi-1 SMAW electrodes are also needed
Companion Materials - Specify if ERNiCu-7 and/or ERCuNi are required for overlay work
Delivery Destination - Domestic India / International Export

Nicorex Alloys stocks ERNi-1, ERNiCu-7, ERCuNi, and matching ENi-1/ENiCu-7 SMAW electrodes for complete Monel and copper-nickel overlay consumable packages.

Frequently Asked Questions

What is the Price of ERNi-1 Welding Wire per kg in India?

ERNi-1 pure nickel welding wire typically ranges from ₹2,500 to ₹3,500 per kg in India, depending on diameter, form, and order quantity. Contact Nicorex Alloys for current pricing.

Why is ERNi-1 Required as a Buffer Layer Before ERNiCu-7 or ERCuNi Overlay on Steel?

Direct deposition of copper-bearing filler metals on carbon steel causes iron dilution. Iron above approximately 5% degrades the NiCu or CuNi weld metal’s corrosion resistance and can form brittle Fe-Cu intermetallic compounds, causing hot cracking. The pure nickel ERNi-1 buffer layer (less than 1% Fe undiluted) acts as a metallurgical barrier, preventing iron from migrating into subsequent overlay passes.

Can ERNi-1 TIG Rod be used for Repairing Cast Iron?

Yes. ERNi-1 is widely used for grey, ductile, and malleable cast iron. The pure nickel deposit is soft (120–150 HB) and fully machinable. Use low amperage, short stringer beads (50 mm max), and peen each bead while hot.

What is the Role of Titanium in the ERNi-1 Filler Metal Composition?

Titanium at 2.0–3.5% serves two functions. It scavenges dissolved oxygen and sulphur to prevent porosity, and it reacts with carbon to form stable TiC, maintaining low free carbon. Both functions matter most when welding Nickel 201 (0.02% C max) and cast iron (high carbon content).

What is the Difference between ERNi-1 and ERNiCu-7 for Monel Overlay Projects?

They are complementary fillers, not alternatives. ERNi-1 (pure nickel, 93%+ Ni, zero Cu) is used only for the first buffer layer on steel. ERNiCu-7 (~65% Ni, ~30% Cu) provides the actual Monel-type corrosion resistance in subsequent passes. Every Monel overlay job requires both ERNi-1 as the barrier and ERNiCu-7 as the functional overlay.

When should ERNi-1 not be used?

Do not use ERNi-1 for oxidising acid service (HNO₃, FeCl₃). Pure nickel performs poorly in these media. It is not suitable above 315°C due to low creep strength. Do not use as the final overlay layer where NiCu or NiCrMo resistance is needed. For Monel-to-Monel joints, use ERNiCu-7.

Does Nicorex Alloys Supply ERNi-1 Alongside ERNiCu-7 and ERCuNi as a Matched Overlay Set?

Yes. Nicorex Alloys stocks ERNi-1, ERNiCu-7, ERCuNi, and matching ENi-1/ENiCu-7 SMAW electrodes as complete consumable packages for Monel and copper-nickel overlay cladding projects.