Waspaloy Welding Wire
- Home
- Welding Consumables
- High Temperature Alloys Welding Wire
- Waspaloy Welding Wire
Waspaloy Welding Wire Supplier in Mumbai, India
Nicorex Alloys is an ISO 9001 and ISO 14001 certified supplier and stockist of Waspaloy TIG filler rods and MIG wire based in Mumbai, India. We provide these welding wires manufactured according to AMS 5828.
The Ni-Cr-Co-Mo-Ti-Al alloy system, containing approximately 58% Ni, 19.5% Cr, 13.5% Co, 4.3% Mo, 3.0% Ti and 1.4% Al, produces roughly a 25% gamma-prime volume fraction and delivers an aged tensile strength of 175-185 ksi (1207-1276 MPa). Waspaloy welding wire (AMS 5828) provides the matching filler for turbine disks in jet engines that rotate at high speeds and operate at about 650°C (1200°F) under sustained high‑temperature service conditions Waspaloy welding wire (AMS 5828) provides the matching filler for turbine disks in jet engines that rotate at high speeds and operate at about 650°C (1200°F) under sustained high‑temperature service conditions. Classified as UNS N07001 (W.Nr 2.4654, ASTM B637, F-43), Waspaloy is specified under AMS only. Waspaloy is sensitive to strain-age cracking and hot-short cracking. Welding must be done in carefully controlled conditions using only GTAW or GMAW with AMS 5828 matching filler. Welds should be avoided in high-stress locations. The base metal must be in the solution-treated condition before welding, then re-solution treated and aged after welding.
Waspaloy filler wire is available as TIG rods and MIG spools in diameters from 0.76 mm to 4.0 mm. MTC 3.1 certificate (EN 10204) confirms compliance with AMS 5828. It is mainly supplied to aerospace gas turbine manufacturers, missile and defence companies, power plants, and high-temperature fastener producers.
Waspaloy Welding Wire Specifications
The table below presents the standard specifications for Waspaloy welding wire, including classification systems and welding parameters.
| AMS | 5828 (bare welding wire) |
|---|---|
| UNS Number | N07001 |
| Werkstoff Nr. | 2.4654 |
| ASTM | B637 |
| SMAW Electrode | No dedicated Waspaloy electrode |
| Welding Processes | GTAW (preferred), GMAW (controlled use only) |
| SAW | Not recommended |
| Polarity | TIG: DCEN | MIG: DCEP |
| Shielding Gas | 100% Argon |
| Preheat | Not required (room temperature) |
Waspaloy Welding Wire Composition (%)
Nicorex Alloys supplies Waspaloy filler wire that meets AMS 5828 limits. Its nickel-based composition is engineered to harden quickly, giving high strength at elevated temperatures.
| Element | AMS 5828 Requirement | Typical |
|---|---|---|
| Nickel (Ni) | Balance | ~58.0 |
| Chromium (Cr) | 18.0–21.0 | 19.5 |
| Cobalt (Co) | 12.0–15.0 | 13.5 |
| Molybdenum (Mo) | 3.5–5.0 | 4.3 |
| Titanium (Ti) | 2.75–3.25 | 3.0 |
| Aluminium (Al) | 1.20–1.60 | 1.4 |
| Iron (Fe) | 2.0 max | 1.0 |
| Carbon (C) | 0.02–0.10 | 0.07 |
| Boron (B) | 0.003–0.010 | 0.006 |
| Zirconium (Zr) | 0.02–0.08 | 0.05 |
| Manganese (Mn) | 0.10 max | 0.03 |
| Silicon (Si) | 0.15 max | 0.05 |
| Phosphorus (P) | 0.015 max | 0.005 |
| Sulfur (S) | 0.015 max | 0.003 |
Titanium (2.75-3.25%) and aluminium (1.20-1.60%) add up to about 4.4%. This drives about 25% gamma-prime formation with fast ageing, giving high peak strength but also causing strain‑age cracking during PWHT heat‑up. Cobalt (12-15%) raises the gamma-prime solvus and strengthens the matrix. Molybdenum (3.5-5.0%) adds solid‑solution strength and forms M₆C grain‑boundary carbides. Zirconium (0.02-0.08%) and boron (0.003-0.010%) further strengthen grain boundaries for long creep life; zirconium is unique to Waspaloy in the Nicorex filler range. Iron is limited to 2.0% max, so the alloy remains fully nickel‑base.
Mechanical Properties of Waspaloy Weld Deposit
Mechanical properties of Waspaloy filler wire, including typical ultimate tensile and yield strength and elongation are provided in the table below:
| Condition | Typical UTS | Typical YS | Typical Elong. |
|---|---|---|---|
| As-Welded (solution annealed) | ~130 ksi (896 MPa) | ~75 ksi (517 MPa) | ~25% |
| Aged (full 3-step Option A) | 145–180 ksi (1207–1276 MPa) | 115–125 ksi (793–862 MPa) | 15–20% |
| Aged hardness | 34–40 HRC | — | — |
Waspaloy Welding Parameters & Heat Treatment
Waspaloy demands strict thermal management before, during and after welding. These parameters apply to GTAW and GMAW with AMS 5828 filler.
| Parameter | Value |
|---|---|
| Welding Processes | GTAW (preferred), GMAW (controlled conditions) |
| Polarity | TIG: DCEN | MIG: DCEP |
| Shielding Gas | 100% Argon |
| Preheat | Not required (room temperature) |
| SAW | Not recommended |
| Welding Condition | Base metal must be solution-treated |
| PWHT | Mandatory — 3-step sequence |
| Service Temperature | ≤650°C (1200°F) rotating; ≤870°C (1600°F) static |
Premium Industrial Materials
Get Waspaloy Welding Wire Prices
ISO Certified
Custom Sizes
Fast Delivery
Industrial Applications of Waspaloy Welding Wire
Nicorex Alloys supplies Waspaloy welding wire to aerospace manufacturers and repair shops for very demanding high‑temperature rotating parts.
- Aerospace Gas Turbines - Rotating & Static Components: AMS 5828 Waspaloy filler is mainly used for compressor and turbine disks, shafts, spacers, seals, rings and casings in gas turbines.
- Missile Systems & Defence: Missile propulsion casings and exhaust parts use Waspaloy because it stays strong and light at high temperatures.
- Fasteners & Springs - High-Temperature Hardware: Bolts, studs, springs and washers used at 500-700°C use special hardening to safely carry loads for long periods.
- Power Generation - Industrial Gas Turbines: Land-based gas turbines use Waspaloy for turbine disks and spacers similar to jet engines, but with longer service intervals.
Storage & Handling of Waspaloy Welding Filler Wire
Nicorex Alloys supplies Waspaloy (AMS 5828) welding wire in protective packaging. No re-baking or reconditioning is required. There is no standard SMAW electrode for Waspaloy.
- Store sealed in a clean, dry area at 15–25°C, below 60% RH. Moisture causes porosity; damp or cold storage areas are not suitable.
- Keep away from carbon steel racks, grinding zones and fabrication areas.
- Store separately from stainless and carbon steel consumables. Shelf life is indefinite in undamaged, sealed original packaging.
- Handle only with clean, lint-free gloves dedicated to nickel alloy consumables. Sulfur and chlorides from fingerprints cause weld cracking.
- Use only dedicated stainless steel or nickel alloy tools.
- Inspect wire before use: must be bright, smooth and free of scale, discolouration or grease. If contaminated, wipe with acetone or IPA.
- Before welding, clean 25 mm (1″) either side of the joint to bright metal with acetone or IPA, then brush with a stainless steel brush. Critical contaminants: sulfur, lead, zinc, copper, tin, and bismuth.
Available Forms & Packaging of Waspaloy Filler Metal
The table below shows the available forms, diameters and packaging options for Waspaloy filler wire
| Form | Diameter Range | Packaging |
|---|---|---|
| TIG Cut Lengths (rods) | 0.76–4.00 mm | cardboard boxes, PVC tubes or plastic-lined tubes |
| MIG Spools | 0.76–2.40 mm | Plastic spools, metal spools and shrink-wrapped cartons |
| Reels | 0.76–4.00 mm | Metal wire reels, wooden reels, palletised wrapping |
| Coils | 0.76–4.00 mm | Plastic-wrapped coils, strapped bundles, pallet packaging |
Sizes ≥3.20 mm are supplied only as TIG rods, not as MIG spools. All Waspaloy filler wire from Nicorex Alloys comes with an MTC 3.1 certificate (EN 10204) confirming that it meets AMS 5828.
How to Order Waspaloy Filler Wire from Nicorex Alloys
Provide the following details in your RQF when placing an order for Waspaloy filler wire:
- Form: TIG rod (preferred) or MIG spool. GTAW is the preferred welding process -confirm if GMAW will be used.
- Diameter: TIG rods 0.76-4.0 mm; MIG wire 0.76–2.40 mm.
- Quantity: In kg or number of tubes/spools. State single-heat requirement if needed.
- Melt Practice: Specify if VIM (vacuum induction melted) or VIM+VAR (vacuum arc remelted) is required.
- Heat/Lot Traceability
- Testing & Certification: (MTC 3.1 per EN 10204 (standard), chemical re-verification, mechanical testing, third-party inspection)
- Packaging: Sealed tubes (TIG), sealed spools (MIG)
- Delivery (Domestic, India/international)
Frequently Asked Questions
Why is Waspaloy difficult to Weld compared to solid-solution nickel Alloys?
Waspaloy contains about 25% fast-forming gamma-prime. During cooling or PWHT, this quickly hardens the heat-affected zone before stresses relax, leading to strain-age cracking.
What PWHT is required after welding Waspaloy?
A full 3-step post-weld heat treatment is mandatory. One way is the creep-optimised cycle, which heats at 1080°C for 4 hours, then 845°C for 24 hours, then 760°C for 16 hours, all with air cooling, giving 34-40 HRC. The other option is the tensile-optimised cycle, which uses 995-1035°C for 4 hours with oil quench, then 845°C for 4 hours and 760°C for 16 hours with air cooling.
Select the first method when creep life is critical and the second method when tensile strength is more important.
Can Waspaloy weld deposits match the strength of the wrought base metal?
No. Even after a full 3-step PWHT, Waspaloy weld metal is usually 10-15% weaker than wrought base metal due to its cast structure. Turbine disk weld repairs must follow strict limits on weld location and size.
What industries procure Waspaloy welding wire?
Mainly used in aerospace gas turbine engines by OEMs and their approved repair shops. Also used by missile and defence manufacturers and for high-performance fasteners.
What is the maximum service temperature for Waspaloy weld deposits?
Use Waspaloy welds up to 650°C for critical rotating parts and 870°C for less demanding static parts. Above 870°C, oxidation increases with higher temperatures.