AWS Class ERZr2 MIG & TIG
ERZr2 Welding Wire Supplier in Mumbai, India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified stockist and supplier of ERZr2 zirconium welding wire based in Mumbai, India. We supply ERZr2 (UNS R60702) bare wire and rods classified under AWS A5.24 / ASME SFA-5.24,
The ERZr2 designation breaks down as ER (electrode/rod), Zr (zirconium), and 2 (Grade 702). The welding wire chemistry holds Zr+Hf at 99.0% min with oxygen controlled at 0.11–0.15%. A self-healing ZrO₂ oxide layer gives this wire acid resistance that surpasses titanium and Hastelloy C-276 in reducing HCl at all concentrations up to boiling. All-weld-metal tensile strength reaches 379 MPa (55 ksi) with 16% min elongation. Welding demands 100% argon (99.995% purity) with mandatory back purge and trailing shield until the joint cools below 260°C (500°F). ERZr2 matches Zircadyne 702 and 705 base metals under ASME P-61 and P-62 groupings. Available as TIG rods in 1.6–3.2 mm and MIG spools in 0.8–1.6 mm, this wire serves chemical processing, pharmaceutical, urea, and nuclear fabrication. Finely divided zirconium is pyrophoric, so storage and fire precautions are mandatory during handling.
As a trader and distributor, Nicorex Alloys stocks ERZr2 in TIG rod and MIG spool forms with full interstitial analysis (O, N, H, C, Fe+Cr, Hf). We provide EN 10204/3.1B mill test certificates on every shipment. ERZr2 is a commercially pure, unalloyed zirconium filler wire that corresponds to the Zircadyne 702 trade designation.
ERZr2 Zirconium Welding Wire Specifications
The specifications for ERZr2 zirconium welding wire, covering classification, shielding, and dimensions, are listed below in the table:
| AWS Classification | ERZr2 (AWS A5.24) |
|---|---|
| UNS | R60702 |
| Processes | GTAW (TIG), GMAW (MIG), PAW |
| Polarity | (TIG): DCEN (MIG): DCEP |
| Shielding Gas | (TIG): 100% Argon (99.995% purity min) (MIG): 100% Argon or Ar/He |
| TIG Diameters | 1.6, 2.0, 2.4, 3.2 mm |
| MIG Diameters | 0.8, 1.2, 1.6 mm |
AWS Classification Explained: ERZr2 (TIG/MIG Wire)
The table below explains the AWS zirconium filler metal designation system, highlighting each element’s meaning and corresponding alloy grade classification.
| Designation | Meaning |
|---|---|
| ER | Electrode/Rod (bare solid wire) |
| Zr | Zirconium |
| 2 | Grade 702 (UNS R60702) |
Commercial-grade zirconium usually has up to 4.5% hafnium, which is fine for normal corrosion‑resistant uses. In contrast, nuclear‑grade Zircaloy must have less than 0.01% hafnium because hafnium absorbs too many neutrons. This makes higher‑hafnium material unsuitable for reactor fuel cladding.
Chemical Composition of ERZr2 Weld Deposit (%)
The chemical composition of ERZr2 per AWS A5.24, along with its proportion in percentage, is listed in the table below:
| Specification | Zirconium + Hafnium (Zr + Hf) | Hafnium (Hf) | Iron + Chromium (Fe + Cr) | Hydrogen (H) | Nitrogen (N) | Carbon (C) | Oxygen (O) |
|---|---|---|---|---|---|---|---|
| AWS A5.24 Req. (%) | 99.0 min | 4.5 max | 0.20 max | 0.005 max | 0.015 max | 0.030 max | 0.11–0.15 |
Hafnium at 4.5% max does not affect corrosion behaviour for chemical service. Fe+Cr held to 0.20% max controls resistance in reducing acids, while the 0.11–0.15% oxygen window balances strength against ductility.
All-Weld-Metal Mechanical Properties of ERZr2 (Zircadyne 702)
The mechanical properties of ERZr2 welding wire, including tensile strength, elongation and yield strength, are listed in the table below:
| Material | Tensile Strength | Yield Strength (0.2%) | Elongation | Density |
|---|---|---|---|---|
| ERZr2 (Zr 702) | 379 MPa (55 ksi) | 207 MPa (30 ksi) | 16% | 6.51 g/cm³ |
ERZr4 offers roughly 45% higher tensile strength through niobium alloying. Zirconium is denser than titanium (6.51 vs 4.51 g/cm³) but delivers superior reducing-acid resistance.
Base Metal Compatibility for ERZr2 TIG Filler Rod & MIG Wire
The base metal and its compatibility, along with grade and P-number, are listed in the table below:
| Base Metal | UNS | P-Number | Notes |
|---|---|---|---|
| Zircadyne 702 | R60702 | P-61 | Primary matching application |
| Zircadyne 705 | R60705 | P-62 | Under-matched; use ERZr4 for a full-strength match |
Zirconium cannot be fusion welded to steel, nickel alloys, copper alloys, or titanium. Brittle intermetallic compounds form with all other structural metals. Dissimilar joints require explosive bonding or flanged connections.
Recommended Welding Parameters for ERZr2 Zirconium Wire
Typical GTAW parameters for ERZr2 are listed below. Gas chamber (glove box) welding is preferred for critical work.
| Wire Diameter | Amps (DCEN) | Volts | Shielding Gas |
|---|---|---|---|
| 1.6 mm | 60–120 A | 10–14 V | 100% Ar (99.995%) |
| 2.4 mm | 100–180 A | 11–16 V | 100% Ar |
| 3.2 mm | 140–250 A | 12–18 V | 100% Ar |
Keep interpass temperature below 150°C. Clean joint surfaces with acetone and handle the wire with lint-free gloves. Weld colour inspection follows titanium standards: silver is acceptable, straw is marginal, blue or grey means contamination and must be rejected.
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Industrial Applications of ERZr2 Zirconium Welding Wire
ERZr2 serves in the following industries where zirconium’s reducing-acid resistance outperforms titanium and nickel alloys:
- Chemical Processing (Hydrochloric Acid Equipment): Reactors, heat exchangers, columns, piping, valves, and pumps.
- Chemical Processing (Sulphuric Acid & Mixed Acid): Equipment that handles sulphuric acid (H₂SO₄) in concentrations up to 70% at high temperatures.
- Acetic Acid & Formic Acid Production: Reactors, distillation columns, and heat exchangers.
- Nuclear Industry: Fuel rod cladding (Zircaloy variants, Hf below 0.01%), reactor core structural components, and spent fuel reprocessing equipment.
- Pharmaceutical & Urea Production: Reactors and piping for API synthesis with corrosive intermediates. Urea carbamate condensers and strippers.
Storage & Handling of ERZr2 Zirconium Welding Wire
Keep the wire in its original sealed packaging until use. Store in a clean, dry area separated from all other metals. Clean with acetone and handle with lint-free gloves. Zirconium chips and dust are pyrophoric: collect machining waste in dedicated containers, never store near water.
Available Forms, Diameters & Packaging of ERZr2 Zirconium Welding Wire
Nicorex Alloys stocks ERZr2 in the following forms, diameters and packaging:
| Form | Diameter | Packaging |
|---|---|---|
| TIG Rod | 1.6, 2.0, 2.4, 3.2 mm | 5 kg sealed tube (914 or 1000 mm length) |
| MIG Spool | 0.8, 1.2, 1.6 mm | 5 kg / 10 kg vacuum-sealed spool |
Surface finish: pickled or polished (bright). EN 10204/3.1B MTC ships with every lot covering O, N, H, C, Fe+Cr, and Hf.
How to Order ERZr2 Zirconium Welding Wire from Nicorex Alloys
To order ERZr2 welding wire from Nicorex Alloys, provide these 9 important details:
- Wire Type: GTAW (TIG) / GMAW (MIG) Solid Wire for Commercially Pure Zirconium Welding
- Size: 1.2mm / 1.6mm / 2.4mm / 3.2mm Evek (GTAW cut lengths / GMAW spools) — specify form
- Current Type: DCEP Evek (GTAW / GMAW)
- Welding Position: All Positions
- Material Grade: Commercially Pure Zirconium / UNS R60702 / AWS A5.24: ERZr2 Evek
- Quantity: Number of spools/packs or total weight in kg
- Standard: AWS A5.24 / ASME SFA 5.24 Certilas, ASME Section IX
- Documentation: MTC 3.1/3.2, PMI Report, Weld Metal Composition Report, TPI Certificate
- Delivery: Domestic
Nicorex Alloys can supply matching ERTi-9 TIG rods and MIG wire from the same certified heat. The full range from ERTi-1 through ERTi-12 is available from stock.
Frequently Asked Questions
What is the difference between ERZr2 (Zr 702) and ERZr4 (Zr 705)?
ERZr2 is commercially pure zirconium (99% Zr+Hf). ERZr4 is alloyed with 2.0–3.0% niobium, raising tensile strength from 55 ksi to 80 ksi and improving hydrogen absorption resistance. ERZr2 suits general chemical processing; ERZr4 is selected for higher-strength or hydrogen-sensitive applications.
Why is Zirconium better than Titanium for Hydrochloric Acid Service?
Titanium’s TiO₂ oxide breaks down in HCl above 3–7% concentration. Zirconium’s ZrO₂ layer is thermodynamically more stable and resists all HCl concentrations (0–37%) up to boiling. No other structural metal matches this.
Can Zirconium be Fusion Welded to Steel or Titanium?
No. Zirconium forms brittle intermetallic compounds with iron, nickel, copper, and titanium. Dissimilar joints require explosive bonding or flanged connections.
Why is Zirconium Pyrophoric?
Finely ground zirconium has a very large surface compared to its size and reacts strongly with oxygen, so it can catch fire by itself. Bulk zirconium (solid wire, plate) is not pyrophoric because the ZrO₂ surface layer prevents runaway oxidation.
What Spool Sizes are available for ERZr2?
TIG rods are available in 914 mm or 1000 mm lengths and are packed in 5 kg sealed tubes. MIG wire comes on 5 kg and 10 kg vacuum‑sealed spools. EN 10204/3.1B MTC with full Hf analysis included.
When not to use ERZr2 Zirconium Welding Wire?
Do not use ERZr2 in nitric acid above 50% (oxidising attack on ZrO₂), hydrofluoric acid (dissolves ZrO₂), or dry chlorine gas (pyrophoric risk). Not suitable for dissimilar fusion welding to steel, titanium, or nickel alloys. For higher strength, use ERZr4.