AWS Class ERNiCu-7 SAW & Flux
AWS A5.14 ERNiCu-7 SAW Wire & Flux Supplier in Mumbai, India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified supplier, importer and stockist of ERNiCu-7 SAW wire and flux in Mumbai, India. We supply this nickel-copper filler metal classified under AWS A5.14 / ASME SFA-5.14, designated as UNS N04060 (EN ISO 18274: S Ni 4060 / NiCu30Mn3Ti).
ERNiCu-7 is a solid bare nickel-copper welding wire with manganese and titanium, and no chromium or molybdenum. At least 62% nickel and about 29-32% copper give the weld good corrosion resistance in reducing acids, seawater, and brackish water. This resistance comes from the natural Ni-Cu alloy chemistry. Titanium (1.5-3.0%) helps remove oxygen from the weld pool, while manganese (2.5-3.5%) helps prevent hot cracking during solidification. Typical weld metal properties are 480-550 MPa (70-80 ksi) tensile strength and 25-35% elongation. ERNiCu-7 is used with a suitable granular flux for submerged arc welding and for nickel-copper overlay or cladding on steel. It is widely used for thick-section Monel heat exchangers, piping, and tube-to-tubesheet joints where high deposition rates are required.
Suitable base metals include Monel 400 (N04400), Monel K-500 (N05500), 70-30 and 90-10 copper‑nickel alloys, plus Monel‑to‑steel joints with an ERNi‑1 buffer layer. Typical applications are marine and offshore, chemical (HF service), desalination, oil and gas, and power generation. Every batch ships with EN 10204‑3.1 MTC and full heat‑lot traceability.
ERNiCu-7 SAW Wire & Flux Specification
Key specifications for ERNiCu-7 SAW wire and flux include classification, standards, welding parameters, and relevant material designations for submerged arc welding applications.
| AWS Classification | ERNiCu-7 |
|---|---|
| AWS Specification | AWS A5.14 / A5.14M:2018 |
| UNS | N04060 |
| Welding Process | SAW (Submerged Arc Welding) |
| Polarity | DCEP (DC Electrode Positive) |
| SAW Flux | Neutral or fluoride-basic type qualified for Ni-Cu alloys |
What Does ERNiCu-7 Mean? - AWS A5.14 Classification Explained
ERNiCu-7 is a nickel‑copper filler metal. Each part of the code shows its form and alloy type.
| Prefix | Meaning |
|---|---|
| E | Electrode — consumable electrode for GMAW and SAW |
| R | Rod — filler rod for GTAW |
| Ni | Nickel — base element (62% min) |
| Cu | Copper — principal alloying element (~29–32%) |
| -7 | Seventh Ni-Cu alloy variant within AWS A5.14 |
The “ER” prefix means the wire can be used as both an electrode (GMAW, SAW) and a rod (GTAW). “Cu” shows it is a nickel‑copper alloy, different from Ni‑Cr and Ni‑Cr‑Mo grades. ERNiCu-7 is a nickel‑based filler for Monel 400, while ERCuNi is a copper‑based filler for 70/30 and 90/10 Cu‑Ni alloys.
Chemical Composition of ERNiCu-7 (AWS A5.14)
This section shows the chemical composition of ERNiCu-7 as per AWS A5.14, focusing on nickel, copper, and other key elements.
| Specification | Nickel (Ni) | Copper (Cu) | Titanium (Ti) | Manganese (Mn) | Iron (Fe) | Silicon (Si) | Carbon (C) | Aluminium (Al) | Phosphorus (P) | Sulphur (S) | Other Elements (total) |
|---|---|---|---|---|---|---|---|---|---|---|---|
| AWS A5.14 Req. (%) | 62.0 min (+Co) | Remainder (~29–32) | 1.5–3.0 | 2.5–3.5 | 2.5 max | 1.25 max | 0.15 max | 1.25 max | 0.020 max | 0.015 max | 0.50 max |
Titanium is the main deoxidiser; it removes oxygen and nitrogen from the molten Ni-Cu weld, reducing porosity. Manganese (2.5-3.5%) improves bead flow and resistance to hot cracking. With no chromium or molybdenum, ERNiCu-7 is not suitable for oxidising acids. In SAW, flux can change Ti and Si levels, so each MTC confirms actual chemistry.
Mechanical Properties of ERNiCu-7 Weld Deposit
This table shows typical as-welded mechanical properties of ERNiCu-7, including strength, elongation, and hardness values.
| Specification | Tensile Strength | Yield Strength (0.2%) | Elongation | Hardness |
|---|---|---|---|---|
| Typical Value (As-Welded) | 480–550 MPa (70–80 ksi) | 275–380 MPa (40–55 ksi) | 25–35% | ~70–80 HRB |
ERNiCu-7 welds cannot be age-hardened. Monel K-500 can reach over 690 MPa by heat treatment, but ERNiCu-7 weld metal cannot be strengthened to that level, which makes K-500 joints weaker at the weld. SAW results may vary slightly from GTAW due to flux effects.
Base Metals Compatible with ERNiCu-7 SAW Wire
The table below shows base metal compatibility for ERNiCu-7 SAW wire, including Monel alloys, copper-nickel grades, and dissimilar metal welding applications.
| Base Metal | UNS | P-Number | Typical Application |
|---|---|---|---|
| Monel 400 | N04400 | P-No. 42 | Primary — seawater piping, HF acid vessels |
| Monel K-500 | N05500 | P-No. 42 | Marine shafting — weld is undermatched in strength |
| Monel R-405 | N04405 | P-No. 42 | Free-machining Monel valve components |
| 70-30 Cu-Ni | C71500 | P-No. 34 | Marine condensers, seawater piping |
| 90-10 Cu-Ni | C70600 | P-No. 34 | Offshore platform seawater systems |
| Nickel 200/201 | N02200/N02201 | P-No. 41 | Dissimilar Ni-to-Ni-Cu joints |
| Carbon steel | — | P-No. 1 | Overlay/cladding — ERNi-1 buffer layer mandatory |
| 300-series SS | S30400/S31600 | P-No. 8 | Dissimilar Ni-Cu to stainless joints |
When overlaying carbon steel, you must first weld a layer of ERNi-1 (pure nickel). If you put ERNiCu-7 directly on steel, carbon moves into the weld and makes it brittle. The ERNi-1 layer blocks this, and ERNiCu-7 is welded on top.
Recommended SAW Welding Parameters for ERNiCu-7
The following table provides typical SAW welding parameters for ERNiCu-7 wire. This helps keep the arc stable and the weld quality consistent in different jobs.
| Electrode Diameter | Current (Amperes) | Voltage (Volts) | Typical Position / Application |
|---|---|---|---|
| 2.4 mm | 220–320 A | 25–29 V | Cladding/overlay (flat position) |
| 3.2 mm | 280–420 A | 27–31 V | Butt joints (flat position) |
| 4.0 mm | 350–500 A | 28–34 V | Heavy section welding (flat position) |
Because copper increases electrical resistance, ERNiCu-7 needs slightly lower amperage than Ni-Cr or Ni-Cr-Mo wires of the same size. Use stringer or narrow weave beads, and keep interpass temperature under 150°C to avoid hot cracking.
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Industries and Applications of ERNiCu-7 SAW Wire & Flux
ERNiCu-7 is used for joining and overlay of Monel 400 for protecting steel from acids, seawater, and alkalis.
- Marine and offshore: Used for welding and overlay of Monel 400 parts on ships, offshore platforms, and seawater equipment.
- Chemical processing: Applied in weld and overlay Monel 400 equipment handling acids, alkalis, and other aggressive chemicals.
- Desalination: Suitable for overlay and joining of Monel 400 tube sheets, tubes, and water boxes in desalination plants.
- Oil and gas: Used in corrosion-resistant applications in wellheads, downhole tools, and process piping.
- Power generation: Applied to Monel 400 feedwater heaters, condensers, and piping exposed to hot, corrosive water.
- Pulp and paper: Used on Monel 400 bleach-plant and recovery equipment exposed to chloride-containing process fluids.
Storage and Handling of ERNiCu-7 SAW Welding Flux
- Store flux in a sealed container in a dry area with humidity below 50%.
- After opening flux, use it within the recommended time or reseal it immediately.
- If flux has been exposed to moisture, rebake it according to the manufacturer’s instructions before using it again.
- Throw away any flux that is clumped, caked, or discoloured.
- Reuse unfused flux only after sieving it and mixing it with fresh flux.
- Keep the wire in its original vacuum-sealed packaging until it is needed.
- Store wire in a dry, clean place, away from dust, oil, and other contaminants.
- Check the ERNiCu-7 wire for any copper oxide tarnish before using it.
- Always handle wire with clean, dry gloves to avoid contamination.
ERNiCu-7 SAW Wire Sizes & Packaging
Below are the available sizes and packaging options for ERNiCu-7 SAW wire, including coils, drums, and matching fluxes.
| Form | Diameters | Packaging |
|---|---|---|
| SAW Wire (coil) | 2.0, 2.4, 3.2, 4.0 mm | 12.5 kg and 25 kg coils |
| SAW Wire (drum) | 2.4, 3.2, 4.0 mm | 100 kg and 250 kg drums |
| SAW Flux | Per manufacturer grade | As per the manufacturer’s packaging |
Each package has a lot-ID label and an EN 10204-3.1 test certificate confirming chemistry to AWS A5.14. All copper-bearing wires are shipped in vacuum-sealed, moisture-barrier packaging from Nicorex Alloys.
How to Order AWS Class ERNiCu-7 SAW & Flux from Nicorex Alloys
When ordering ERNiCu-7 nickel-copper SAW wire from Nicorex Alloys, specify the following in your RFQ:
- AWS Classification & UNS: ERNiCu-7 / UNS N04060
- Product Form: SAW wire, flux, or wire + flux combo
- Wire Diameter: 2.0, 2.4, 3.2, or 4.0 mm
- Flux Type & Grade: specify or request Nicorex recommendation
- Spool/Coil/Drum Packaging: weight and type
- Applicable Standard: AWS A5.14 / ASME SFA-5.14 or project spec
- Base Metal Application: e.g., Monel 400 butt joint, Cu-Ni overlay on CS, dissimilar joint
- Quantity: kg or number of packages
- Documentation: EN 10204-3.1 MTC, CoC, SDS, batch test certificate
- Packaging & Delivery Destination: Domestic / International
Frequently Asked Questions
What is the difference between ERNiCu-7 and ERNiCrMo-3?
ERNiCu-7 (UNS N04060) is a nickel-copper filler for Monel 400 and copper nickel alloys. ERNiCrMo-3 (UNS N06625) is a nickel chromium molybdenum for harsh acid and chloride service.
Which flux is recommended for ERNiCu-7 submerged arc welding?
Neutral or fluoride basic fluxes qualified for nickel-copper alloys are recommended. There is no AWS standard flux for nickel alloys.
Can ERNiCu-7 SAW be used for welding 70-30 and 90-10 Cu-Ni alloys?
Yes. ERNiCu-7 is suitable for 70-30 and 90-10 copper nickel alloys and is widely used for seawater piping and marine condenser tubes.
Is ERNiCu-7 suitable for hydrofluoric acid (HF) service?
Yes. Monel 400 and nickel-copper alloys are standard for hydrofluoric acid service. ERNiCu-7 weld metal matches Monel 400 performance in refinery alkylation units.
What is the maximum interpass temperature for ERNiCu-7 SAW?
The maximum interpass temperature for ERNiCu-7 submerged arc welding is 150°C to reduce hot cracking from copper-rich grain boundary segregation.
Can ERNiCu-7 be used in oxidising acid environments?
No. Nickel-copper alloys perform poorly in oxidising acids such as nitric acid, hot concentrated sulfuric acid and chromic acid.