Nickel Alloy Welding Consumables Selection Guide

By Shanghai Hangbo Alloy Group Co., Ltd. - China Supplier | ISO 9001:2015 | Est. 2012

Contact: sales@hangboalloy.com | hangbo@nickel-alloy.com | WhatsApp (Lisa): +86 13611656360

Quick Answer: Filler Metal Selection

Match the filler metal to the parent metal first, then to the dilution it will see in service. ERNiCrMo-3 covers 625, 718, dissimilar steel and overlay; ERNiCrMo-4 covers C-276; ERNiCr-3 covers 600, 601 and 800H; ENiCrFe-3 and ERNiCu-7 cover 600, 800 and Monel 400 or K-500.

Key Takeaways

• The consumable is a separate design decision from the parent metal. A joint in Alloy 625 is not automatically welded with 625 wire, and a dissimilar joint is rarely welded with a filler that matches either parent metal. The filler is selected for the weld metal it must produce after dilution, not for the plate it sits next to.
• Dilution is the controlling variable in overlay and dissimilar work. The weld metal that actually forms is a mixture of filler and melted parent metal, and on a carbon steel or low-alloy substrate that mixture can carry 15–30 % iron in the first layer, which is often enough to remove the corrosion resistance the overlay was specified for.
• Every nickel consumable has a narrow thermal window. ERNiCrMo-4 (C-276) precipitates secondary phases between roughly 600 °C and 1000 °C; Alloy 718 is liable to strain-age cracking (SAC) after welding during the ageing cycle; Monel K-500 loses titanium and niobium to the arc and to overheating. Heat input and interpass temperature are therefore written into the procedure, not left to the welder.
• Classification standards are not interchangeable. AWS A5.14 covers nickel alloy bare wire and rod, AWS A5.11 covers covered electrodes, and the two must be cited together with the parent-metal product standard so that both sides of the joint are controlled.
• Common failures are predictable. Hot cracking, porosity, lack of fusion and dilution-driven loss of corrosion resistance account for most rejected nickel welds, and each has a specific countermeasure in the welding procedure specification.
• Procedure qualification is the enforcement mechanism. ASME BPVC Section IX requires the WPS and PQR to demonstrate that the selected consumable, in the selected condition, meets the specified properties after the actual dilution of the joint.

Why Filler Metal Selection Is a Separate Engineering Decision

Nickel alloy welding is usually discussed as if the only question were which wire matches the plate. In practice the plate and the wire are two different problems. The parent metal is chosen for its resistance to a process stream at a temperature, and its composition is fixed by a product standard. The filler metal is chosen for the weld metal that will exist after the arc has melted some of the parent metal into the joint and after the weld has been through whatever thermal cycle the fabrication sequence imposes. On a simple butt joint in 625 plate, the two choices happen to coincide closely, and that is why the simplest case is a poor model for the rest. On a 625 overlay on carbon steel, a dissimilar joint between 625 and 316L, or a Monel K-500 component that will be aged after welding, the filler and the parent metal are governed by entirely different rules.

The reason the distinction matters commercially is that the failure mode of a badly selected consumable is not a weld that looks wrong. It is a weld that passes visual and radiographic inspection, passes the hydrostatic test, and then fails in service six to twenty-four months later by preferential corrosion of the weld metal, by cracking at the fusion line, or by loss of strength in a heat-affected zone that was never properly considered. Nickel alloys are specified when the service is aggressive; a marginal weld in an aggressive service is a reliability problem with a long lead time before it becomes visible.

Four variables govern the decision. The first is the parent metal combination, because a dissimilar joint forces the filler to be selected for compatibility with both sides and for the dilution it inherits from both. The second is the dilution ratio, which is a function of the welding process, the joint geometry, the number of passes and the travel speed, and which determines whether the deposited composition is still within the corrosion envelope of the intended alloy. The third is the thermal cycle, including preheat where it is used, interpass temperature, heat input and any post-weld heat treatment, because the nickel alloy families respond to heat in different and sometimes opposite ways. The fourth is the qualification and documentation route, because a consumable that is correct on paper but not covered by a qualified procedure is not usable in code work. The sections that follow treat each of these in turn, and the tables give the matching rules, parameters and verification references that can be written directly into a welding procedure specification.

Common Nickel Filler Metal Grades and Their Matching Parent Metals

The nickel filler metal family is small compared with the stainless steel family, and most industrial welding is covered by fewer than a dozen classifications. The two that appear on the largest number of drawings are ERNiCrMo-3, the 625-type wire, and ERNiCr-3, the 600-type wire. Between them they cover the great majority of dissimilar joints, overlays and high-temperature fabrications, and the choice between them turns on the molybdenum and niobium content that the service requires.

ERNiCrMo-3 is the workhorse of the family. Its deposited composition is approximately 62 % nickel, 22 % chromium, 9 % molybdenum and 3.5 % niobium plus tantalum, which reproduces the 625 base composition closely enough that the weld metal resists the same oxidising and mixed-acid environments, keeps useful strength to about 650 °C, and tolerates the dilution it absorbs from carbon steel, low-alloy steel, stainless steel and 9 % nickel steel. That combination is why it is the default filler for overlay cladding, for dissimilar joints between stainless and carbon steel where the service is corrosive, and for welding 625, 718, 925 and 725 components. The niobium addition is also the reason it must not be used in the wrong thermal regime: a niobium-bearing nickel weld metal held in a sensitising temperature range can precipitate phases that reduce ductility and corrosion resistance.

ERNiCr-3 is the chromium-nickel filler used for the 600 and 800 families. It deposits roughly 67 % nickel, 20 % chromium and 3 % iron with about 2.5 % niobium plus tantalum, and it is specified where the parent metal is 600, 601, 800, 800H or 800HT, where the joint is between these alloys and a stainless or carbon steel, and where the service temperature is high enough that the niobium-stabilised structure is an advantage. It is not a substitute for ERNiCrMo-3 in molybdenum-dependent corrosion service, because it contains essentially no molybdenum and will not resist pitting or crevice attack in chloride-bearing streams.

The copper-bearing family is used almost exclusively for the nickel-copper alloys. ERNiCu-7 and its electrode equivalent ENiCu-7 deposit approximately 65 % nickel and 30 % copper with titanium and manganese additions, which give the weld metal the reducing-environment and seawater resistance of Monel 400 while providing the deoxidation and strength that the arc needs. They are the standard consumables for Monel 400 and Monel K-500 fabrications, including K-500 components that will be age hardened after welding.

Filler metal (AWS class)	UNS	Nominal deposited composition (wt %)	Typical parent metals	Standard
ERNiCrMo-3	N06625	~62Ni-22Cr-9Mo-3.5Nb	625, 718, 925, 725, dissimilar steel, overlay on carbon steel	AWS A5.14
ERNiCrMo-4	N10276	~57Ni-16Cr-16Mo-4W	C-276, C-22, C-2000, dissimilar nickel-chromium-molybdenum joints	AWS A5.14
ERNiCr-3	N06082	~67Ni-20Cr-3Fe-2.5Nb	600, 601, 800, 800H, 800HT, dissimilar joints	AWS A5.14
ERNiFeCr-2	N07718	~53Ni-19Cr-3Mo-5Nb	Alloy 718, 706	AWS A5.14
ERNiCu-7	N04060	~65Ni-30Cu-3.5Ti	Monel 400, Monel K-500	AWS A5.14
ENiCrFe-3	W86082	~67Ni-15Cr-8Fe-2Nb (covered electrode)	600, 800, dissimilar joints	AWS A5.11
ENiCu-7	W84060	~65Ni-30Cu-3Ti (covered electrode)	Monel 400, Monel K-500	AWS A5.11
ENiCrMo-4	W80276	~57Ni-16Cr-16Mo-4W (covered electrode)	C-276, C-22	AWS A5.11

Table note: Compositions are nominal deposited-chemistry values typical of the AWS classifications named in the final column and are given as guidance; the acceptance limits are those of the AWS specification and of the product data sheet issued with the actual lot, which may vary within the classification range. ERNiCrMo-4 is the tungsten-bearing variant of the C-276 system and must not be confused with ERNiCrMo-3 on the basis of the class number alone, because the molybdenum content of the two differs by roughly 7 % and the corrosion behaviour differs accordingly. Filler metal lots supplied for code work are normally certified to AWS A5.14 or A5.11 and to the equivalent GB, JIS, DIN or EN and GOST classifications where the project specification names them, with inspection documents to EN 10204. Our Hastelloy range and Inconel range cover the matching parent metals for the fillers listed here.

The matching rule that follows from the table is simpler than the table itself. Match the filler to the more highly alloyed side of the joint where the two sides differ, because the lower-alloyed side contributes dilution but does not contribute corrosion resistance. Where both sides are the same nickel alloy, use the matching filler unless dilution or a high-temperature ageing cycle makes a more highly alloyed filler preferable. Where one side is carbon steel or a low-alloy steel, use a nickel-based filler rather than an austenitic stainless filler, because the nickel filler accommodates the dilution better and produces a weld metal whose ductility and thermal expansion match the nickel or stainless side more closely.

Parent metal (UNS)	Recommended wire	Recommended electrode	Dilution tolerance and notes	Standard basis
Alloy 625, N06625	ERNiCrMo-3	ENiCrMo-3	matching filler; overlay first-layer dilution must be controlled	ASTM B443 / AWS A5.14 / A5.11
Alloy 718, N07718	ERNiFeCr-2	ENiCrFe-2 / ENiCrFe-3	filler must age with the parent; avoid SAC thermal cycle	ASTM B637 / AWS A5.14
Hastelloy C-276, N10276	ERNiCrMo-4	ENiCrMo-4	low heat input; no PWHT; interpass control is critical	ASTM B575 / AWS A5.14 / A5.11
Inconel 600, N06600	ERNiCr-3	ENiCrFe-3	matching filler; tolerant of moderate dilution	ASTM B168 / AWS A5.14 / A5.11
Incoloy 800H, N08810	ERNiCr-3	ENiCrFe-3	matching filler; also used for dissimilar joints to stainless	ASTM B407 / AWS A5.14 / A5.11
Monel 400, N04400	ERNiCu-7	ENiCu-7	matching filler; copes with dilution from carbon steel	ASTM B164 / AWS A5.14 / A5.11
Monel K-500, N05500	ERNiCu-7	ENiCu-7	matching filler; age after welding; control heat input	ASTM B865 / AWS A5.14 / A5.11
316L stainless to carbon steel	ERNiCrMo-3	ENiCrMo-3	nickel filler preferred over 309L for corrosive service	ASME IX / AWS A5.4
625 overlay on carbon steel	ERNiCrMo-3	ENiCrMo-3	first-layer Fe control governs acceptance	ASME IX / AWS A5.14

Table note: The recommendations are the conventional industrial practice for the parent metal pairs shown and are based on the deposited compositions in the previous table together with the dilution behaviour of each filler family; the mandatory filler designation and the qualified dilution limit for a specific joint are those stated in the qualified welding procedure specification, which is normally qualified to ASME BPVC Section IX. Where a joint combines two of the alloys listed, the filler is selected for the more highly alloyed side, and where corrosion resistance is the governing requirement the procedure must demonstrate the weld metal chemistry at the depth the service will expose. Carbon and low-alloy steel sides contribute iron to the weld metal and must be accounted for in the dilution calculation, not assumed away.

AWS A5.14 and A5.11: How Nickel Consumables Are Classified

Nickel alloy consumables are classified by product form rather than by alloy family, and the two specifications that matter are AWS A5.14 for bare wire and rod and AWS A5.11 for covered electrodes. Neither covers stainless steel or carbon steel fillers, which are handled by AWS A5.9 and A5.18 and by AWS A5.4 for stainless covered electrodes; that separation matters because a dissimilar steel joint can legitimately use a consumable from either side of the boundary, and the choice changes the corrosion and strength behaviour of the joint.

AWS A5.14, Specification for Nickel and Nickel-Alloy Bare Welding Electrodes and Rods, covers the bare wire, rod and cut-length products used for gas tungsten arc welding, gas metal arc welding, submerged arc welding and the wire-feed overlay processes. Its classifications carry the prefix ER, standing for electrode or rod, and are written as ER followed by the alloy designation — ERNiCrMo-3, ERNiCrMo-4, ERNiCr-3, ERNiFeCr-2 and ERNiCu-7 are the classes that appear most often on fabrication drawings. The specification sets the required composition ranges, the supplied form and temper, the surface condition and, for the wire products, the spool and coil packaging conventions. It does not set welding parameters; the heat input, the shielding gas and the interpass temperature are established by the procedure qualification.

AWS A5.11, Specification for Nickel and Nickel-Alloy Welding Electrodes for Shielded Metal Arc Welding, covers the flux-covered electrodes used in manual metal arc welding. Its classifications carry the prefix E and are distinguished by the flux coating type and by the composition of the deposited metal — ENiCrFe-3, ENiCu-7 and ENiCrMo-4 for the common nickel consumables. Covered electrodes deposit weld metal with a somewhat different composition from the matching bare wire because the flux contributes to the slag and to the alloy recovery, and because the arc atmosphere affects the recovery of reactive elements such as titanium and niobium. That difference is why an electrode classification is not automatically interchangeable with the wire of similar nominal chemistry, and why a procedure qualified with wire must not be operated with a covered electrode without requalification.

Standard	Classifies	Product form	Designation example
AWS A5.14 / ASME SFA-5.14	Nickel and nickel alloy bare electrodes and rods	bare wire, rod, cut length	ERNiCrMo-3
AWS A5.11 / ASME SFA-5.11	Nickel and nickel alloy covered electrodes	flux-covered electrode	ENiCrFe-3
AWS A5.4 / ASME SFA-5.4	Stainless steel covered electrodes	flux-covered electrode	E309L-16 for the steel side of a dissimilar joint
ASME BPVC Section IX	Welding procedure and performance qualification	procedure, welder	WPS, PQR, WPQ
ASME BPVC Section IIC	Welding rods, electrodes and filler metals	adoption of AWS classifications into the code	SFA-5.14, SFA-5.11
ISO 18274 / ISO 14171 / ISO 14343	Welding consumables for nickel alloys, for non-alloy steels and for stainless steels	bare wire and rod	ISO 18274 classification of nickel wire
DIN 1736	Welding consumables for nickel and nickel alloys	wire and electrode	DIN 1736 designation
GB/T 15620 / GB/T 13814	Nickel and nickel alloy welding wire; nickel and nickel alloy covered electrodes	wire; electrode	GB/T 15620 wire, GB/T 13814 electrode
JIS Z 3334	Nickel and nickel alloy welding wire and rod	bare wire, rod	JIS Z 3334 designation
GOST 2246	Welding wire, general classification	bare wire	GOST 2246 (steel-wire classification; check nickel applicability, 待核)

Table note: The standards are listed by number and scope; the controlling edition is the one named in the purchase order or project specification, and where two classification systems are named for the same consumable both must be satisfied. ISO 18274 is the nickel-specific welding consumables standard, while ISO 14171 and ISO 14343 classify wire electrodes for non-alloy steels and for stainless steels respectively, so they are relevant to a dissimilar joint only through the steel side. AMS 5832-class specifications are quoted for some high-temperature nickel welding wire; the numbering of the correct AMS product specification should be verified against the current AMS index before it is written into a purchase order (待核). Certification of the consumable lot to EN 10204 and the parent metal product standards — ASTM B443 for 625 plate and sheet, ASTM B575 for C-276 plate and sheet, ASTM B637 for precipitation-hardening nickel bar such as 718, ASTM B164 for Monel 400 bar and ASTM B865 for Monel K-500 — complete the documentation chain from plate to weld.

The practical consequence of the classification split is that a welding procedure for a nickel alloy joint normally cites at least three standard numbers: the parent metal product standard on each side, the consumable classification, and the qualification code. A procedure that cites only the filler classification has not fixed the parent metal properties, and a procedure that cites only the parent metal standards has not fixed the deposited composition. Both gaps are regularly found in incoming documentation, and both are resolved the same way, by requiring the complete standard set in the procedure specification and in the material certificates, with EN 10204 inspection documents that identify the actual heat and lot.

Dilution, Weld Overlay and Dissimilar Steel Joints

Dilution is the fraction of the deposited weld metal that comes from the melted parent metal rather than from the filler. It is the single most important number in overlay and dissimilar-metal welding, and it is the number most often left out of a welding procedure. A weld metal that nominally contains 22 % chromium from the filler can end up with 14 % chromium after dilution, and at that level the alloy no longer resists the chloride pitting or oxidising acid service for which it was chosen. The corrosion resistance is not degraded gradually; it falls off a cliff once the chromium, molybdenum and nickel levels drop below the thresholds that sustain the passive film.

Dilution is controlled by process and technique rather than by the filler alone. Gas tungsten arc welding with cold wire produces the lowest dilution of the common processes, typically 10–20 % on a well-prepared joint; gas metal arc welding and flux-cored arc welding sit in the middle; submerged arc welding and the high-deposition overlay processes produce the highest, and in a single-pass autogenous or high-current overlay the dilution can exceed 30 %. Joint geometry matters as much as process: a wide, open groove or a deep, hot weld pool pulls in more parent metal than a narrow one. Travel speed, current, oscillation width and electrode angle all act on dilution, and the countermeasures that reduce it — lower current, faster travel, stringer rather than weave beads, controlled oscillation, more passes, lower interpass temperature — are the same measures that reduce heat input. That convergence is the reason the two topics are usually specified together.

In overlay cladding, the amount of dilution falls as the number of layers rises. The first layer on a carbon steel or low-alloy steel substrate carries the highest iron content, because it sits directly against the substrate and absorbs the most melting; the second and third layers approach the nominal filler composition. The practical rule is that corrosion resistance is assessed on the composition of the layer that the process stream will actually see, after any subsequent machining or grinding, and not on the nominal filler composition. Where a 625 overlay is required to resist a chloride-bearing stream, many specifications therefore require the first layer to be deposited at controlled dilution and a defined iron content to be achieved at the specified depth, with the chemistry verified on a sample taken before or at the surface. The acceptance criterion is written in terms of iron and of the alloying elements, using the applicable product standard composition as the reference, and it is checked on a coupon welded with the production procedure rather than on the production part after the fact.

The same logic drives dissimilar-metal joint design. When 625 or 316L is welded to carbon steel, the weld metal inherits iron from the carbon steel side, and when two stainless steels of different compositions are joined the chromium and nickel balance shifts. The filler is chosen for the more highly alloyed side, and where the service is corrosive a nickel-based filler is preferred over an austenitic stainless filler because the nickel weld metal tolerates more dilution before its properties fall below the acceptance line. The nickel filler also matches the thermal expansion of the austenitic and nickel side more closely than a carbon or low-alloy steel metal would, which reduces the residual stress that drives cracking in a joint between materials with different expansion behaviour. Where the joint will cycle in temperature, the qualified procedure should include mechanical testing of the joint rather than of the parent metals separately, because it is the weld metal and the fusion boundary that carry the risk. The Hastelloy range supplies both the C-276 plate and the ERNiCrMo-4 wire for these joints, and the Monel range covers the nickel-copper case.

Welding Each Family: 625 Overlay, C-276, 718 and Monel K-500

The four alloys that cause the most welding difficulty each fail for a different reason, and the countermeasures are specific to each. Treating them as one class of "difficult nickel alloys" produces procedures that solve the wrong problem.

Alloy 625 and its filler ERNiCrMo-3 are relatively forgiving, and the difficulty lies in the overlay rather than in the butt joint. The niobium addition that gives the alloy its strength and pitting resistance also makes the weld metal sensitive to the thermal cycle, and the practical controls are moderate heat input, a low interpass temperature, clean joint faces and a shielding gas that keeps oxygen and nitrogen out of the pool. In overlay work the dominant issue is dilution and the iron content of the first layer, as described above. For a 625 overlay on carbon steel, the first layer is normally deposited with a low-dilution process and the specified iron level is met by controlling current, travel speed and number of passes rather than by accepting whatever chemistry the arc produces. Where the overlay must also survive high temperature, the deposited niobium content must be sufficient after dilution, which is another reason the first layer is the critical one.

Hastelloy C-276, welded with ERNiCrMo-4 or ENiCrMo-4, is the alloy that punishes excessive heat most severely. The weld metal precipitates secondary phases — the mu and P phases — in the range from roughly 600 °C to 1000 °C, and the time spent in that range determines how much forms. The consequence is loss of corrosion resistance and of ductility in the weld metal and in the heat-affected zone, exactly in the alloy chosen for the most aggressive service. The controls are a low heat input, a tightly limited interpass temperature, a minimum number of passes, and the avoidance of post-weld heat treatment unless it is specifically required and specifically qualified. Where PWHT is unavoidable, it is performed as a solution anneal with a rapid quench, which is a very different operation from the stress relief applied to carbon steel and must be covered by a qualified procedure. The Hastelloy C-276 article covers the parent-metal side of these joints.

Alloy 718, welded with ERNiFeCr-2 or with a nickel-chromium-iron electrode depending on the procedure, suffers from strain-age cracking. The mechanism is that the weld and the heat-affected zone are in a state of high residual stress after welding, and when the component is aged the precipitation hardening reaction begins while the material is still ductile enough to accommodate only limited strain and while the residual stress is still high. The result is intergranular cracking during the ageing cycle rather than in service. The standard countermeasures are to control the weld thermal cycle so that the heat-affected zone is not left in an unfavourable state, to minimise restraint in the joint design, to avoid preheat and to use a controlled heating rate into the ageing temperature, and in many cases to accept a solution anneal followed by ageing rather than ageing directly after welding. Because the failure occurs during a furnace cycle, it is often invisible until the parts are inspected after heat treatment, and the inspection should be planned accordingly.

Monel K-500 is welded with ERNiCu-7 or ENiCu-7 and is aged after welding to develop its strength. Two problems arise. The first is that the titanium and, where present, the niobium additions are reactive and can be lost to oxidation in the arc or to overheating, which shifts the weld metal composition and reduces its response to the ageing treatment. Shield quality, arc length and heat input therefore control the composition of the deposit, and the aluminium and titanium contents of the aged weld metal should be confirmed rather than assumed. The second is the same class of problem as in 718 in weaker form: a K-500 fabrication is aged as a whole component, and the weld must age with the parent metal if the joint is to carry the design load. Where a K-500 component cannot be aged after welding, the design should either accept the lower as-welded strength or change the alloy, because welding alone does not produce the age-hardened condition.

Preheat, Interpass Temperature, Shielding Gas and Heat Input

Nickel alloys are austenitic and do not suffer hydrogen-assisted cold cracking the way low-alloy steels do, so preheat is generally not required for the nickel alloy side of a joint. Where preheat is applied it is usually for the carbon or low-alloy steel side of a dissimilar joint, for thick sections, or to drive off surface moisture on a cold or humid site. The more important thermal control is the interpass temperature, which is a maximum rather than a minimum. For the nickel-chromium-molybdenum consumables, and especially for ERNiCrMo-4, the interpass temperature is typically held at or below about 100–150 °C so that the weld metal does not spend time in the secondary-phase precipitation range. For ERNiCr-3 in high-temperature service the limit is looser, but a high interpass temperature still increases the time at temperature and the risk of niobium-bearing phase formation.

Heat input is the product of arc voltage, current and efficiency divided by travel speed, and it is the variable that most directly controls how long the weld and heat-affected zone stay hot. For nickel alloy welding the customary range is roughly 0.5–1.5 kJ/mm for manual and semi-automatic work, with the lower half of the range preferred for C-276, 718 and the copper-bearing fillers, and the middle of the range acceptable for ERNiCr-3 and ERNiCrMo-3 in straightforward joints. Very low heat input should not be chased as a virtue: it increases the cooling rate, raises the risk of lack of fusion and of a cold lap at the fusion boundary, and produces a weld that looks acceptable but is not bonded. The heat input limits belong in the procedure together with a maximum interpass temperature and a maximum deposit thickness per pass.

Shielding gas selection follows the process. Argon is the default for gas tungsten arc and gas metal arc welding of nickel alloys, and it gives good arc stability and a clean weld pool. Argon-helium mixtures are used where more heat is wanted — heavier sections, more fluid weld pool and better wetting, faster travel on overlay — at the cost of a hotter arc and a greater tendency to dilution, which must then be controlled by technique. Argon-hydrogen mixtures are used mainly on austenitic materials to improve wetting and reduce surface oxide; a hydrogen addition of up to about 5 % is the customary limit, and it must be used with care on the nickel families because excessive hydrogen can contribute to porosity and is not appropriate for the oxygen-sensitive copper-bearing fillers. Backing and trailing shields are used on the more reactive alloys to protect the hot metal from air until it has cooled, and the shielding gas flow rate must be high enough to exclude air but not so high that it draws air into the plume.

Process	Typical filler	Preheat	Interpass (max)	Heat input guide	Shielding / backing	Standard basis
GTAW manual, 625 joint	ERNiCrMo-3	none typical	~150 °C	~0.5–1.2 kJ/mm	Ar; Ar+He for thicker sections	ASME IX qualification
GTAW overlay, 625 on carbon steel	ERNiCrMo-3	none typical	~150 °C	low, stringer beads for dilution control	Ar; trailing shield on reactive grades	ASME IX; ASTM B443 reference chemistry
GMAW, 625 or 718	ERNiCrMo-3 / ERNiFeCr-2	none typical	~150 °C (718 lower)	~0.6–1.5 kJ/mm	Ar with small He addition	ASME IX
SMAW, root and fill	ENiCrFe-3 / ENiCrMo-4	none typical	~100–150 °C	~0.6–1.5 kJ/mm	n/a (flux)	AWS A5.11; ASME IX
GTAW / GMAW, C-276	ERNiCrMo-4	none	~100 °C preferred	low, ≤ ~1.0 kJ/mm	Ar; high-purity	AWS A5.14; ASTM B575 reference chemistry
GTAW / GMAW, Monel K-500	ERNiCu-7	none	~150 °C	moderate, avoid overheating	Ar; avoid H2 additions	AWS A5.14; ASTM B865
SAW overlay, 625 or 316L band	ERNiCrMo-3 strip, 316L strip	n/a	~150 °C	high deposition, dilution controlled by layer	agglomerated flux	ASME IX

Table note: The values are customary industrial shop ranges and are given as guidance; the mandatory limits are those established by the qualified welding procedure specification, normally qualified to ASME BPVC Section IX using consumables classified to AWS A5.14 for wire and A5.11 for covered electrodes, and confirmed against the parent metal product standard — ASTM B443 for 625, ASTM B575 for C-276, ASTM B637 for Alloy 718 and ASTM B865 for Monel K-500. Where a procedure specifies a maximum interpass temperature, that limit is verified with a contact thermometer or an approved measuring device on the production joint, not on a test piece. Heat input is a calculated value in the WPS and a monitored value in production, and on the C-276, 718 and copper-bearing families it is treated as a critical variable rather than as a convenience.

Weld Defects, Post-Weld Heat Treatment and Qualification

The defects that reject nickel alloy welds are few and well understood. Hot cracking, or solidification cracking, occurs in the weld metal when low-melting constituents segregate at the centre of the pool and the weld metal cannot accommodate the strain imposed as it solidifies. In nickel alloys the elements that raise the risk are sulphur, phosphorus and, in some families, silicon and niobium; the countermeasures are to keep the base metal and filler clean of these elements, to control the weld bead shape so that the pool does not finish with a deep, narrow, high-strain centre, to use a filler that dilutes the sensitive elements, and to avoid excessive restraint. Where the parent metal is a casting with high sulphur or a free-machining grade, hot cracking risk rises sharply and the procedure should call for the affected layer to be removed before welding.

Porosity is the defect most often found by radiography, and in nickel welding it usually comes from nitrogen, oxygen or hydrogen picked up from the atmosphere, from moisture in the flux or on the joint faces, or from surface contamination such as oil, paint, marking fluid or the residue of a machining lubricant. Nickel alloys, and especially the copper-bearing fillers, are sensitive to gaseous contamination because their weld pools are more viscous and slower to release gas than a steel pool. The countermeasures are meticulous cleaning immediately before welding, the correct shielding gas flow and gas cover for the joint configuration, the use of backing and trailing shields on reactive alloys, low dew-point gas, and dry, correctly stored electrodes.

Lack of fusion and incomplete penetration are the third common family of defects, and they become more likely when heat input is reduced in an attempt to control dilution or interpass temperature. A very fluid nickel weld pool can bridge a poorly prepared edge and leave an unbonded lap that radiography may not detect reliably; ultrasonic or other volumetric techniques, or a disciplined visual and dye-penetrant inspection of the accessible faces, are needed to find it. The countermeasures are the correct joint preparation and fit-up, adequate heat input for the section, the correct electrode angle and weaving technique, and a check that the reduced heat input still produces a sound bond. To these three families should be added corrosion-related defects, which are not detected by mechanical inspection at all: an overlay whose first-layer iron content is above the specified level, a dissimilar joint whose deposit composition after dilution has fallen below the corrosion envelope, or a C-276 weld metal that has been held in the precipitation range. Each is prevented by the procedure and confirmed by a coupon, not by inspection of the finished part.

Defect	Typical cause	Countermeasure	Where it is checked
Solidification (hot) cracking	S, P, Si segregation; deep narrow bead; restraint	clean consumables, bead shape control, less restraint, suitable filler	procedure qualification coupon; PT
Porosity	moisture, oil, marking fluid, poor shielding, wet flux	clean joint, correct gas flow, backing shield, dry electrodes	RT, VT; procedure coupon
Lack of fusion / incomplete penetration	low heat input, poor fit-up, wrong technique	adequate heat input, correct joint prep and angle, qualified technique	UT / RT / PT as applicable
Loss of corrosion resistance	excessive dilution, wrong filler, secondary-phase precipitation	dilution control, correct filler, interpass limit, no unjustified PWHT	first-layer chemistry coupon to ASTM reference
Strain-age cracking (718)	residual stress plus ageing cycle	controlled thermal cycle, low restraint, controlled heating rate	inspection after ageing
Ti / Nb loss in Monel K-500	arc oxidation, overheating	shielding control, heat input control, low arc length	chemistry check on aged weld metal

Table note: The defect list is drawn from the failure modes most commonly reported for the alloy families in this article; the acceptance criteria for each defect are those of the applicable fabrication code, and for ASME work the inspection methods and acceptance levels follow ASME BPVC Section V and Section VIII, Division 1 or Division 2 as specified. The corrosion-related entries are not covered by routine mechanical inspection and must be controlled through the procedure and verified on a coupon — first-layer chemistry on overlays, deposit chemistry on dissimilar joints — using the composition limits of the applicable product standard, ASTM B443 for 625 and ASTM B575 for C-276, as the reference. Where a nickel alloy joint needs post-weld heat treatment at all, it is normally for stress relief on a specific service rather than as a routine requirement; on the C-276 system PWHT should generally be avoided, and where it is required it takes the form of a solution anneal with rapid quench, qualified to ASME BPVC Section IX.

The qualification decision is what ties the whole selection together. A welding procedure specification states the parent metals and their product standards, the consumable classification, the process, the joint design, the preheat and interpass limits, the heat input range, the shielding gas and the post-weld heat treatment. The procedure qualification record, produced to ASME BPVC Section IX, demonstrates by test that a weld made exactly to that specification delivers the required strength, ductility and, where specified, corrosion resistance. For nickel alloys the corrosion-related requirement is the one that is most often omitted from the qualification, because the code test is mechanical. Where the reason for specifying the alloy is corrosion resistance, the procedure qualification should be extended to include a deposit chemistry check, and where the service is aggressive, a corrosion test with an agreed criterion. That addition is what makes the qualification meaningful for the service rather than merely compliant with the code. Our other materials articles cover the parent-metal side of these decisions, and the knowledge base explains the documentation route from mill certificate to weld qualification.

Applications, Selection and Cost Reference (2026, EXW Shanghai)

The selection rules come together in the form of an application table, because most fabrications can be matched to a known duty. The table below sets out the common applications, the filler that is conventionally specified and the reason.

Application	Parent metals	Typical filler	Reason	Alternative
FGD duct and absorber overlay	carbon steel + 625 overlay	ERNiCrMo-3	oxidising acid plus chloride resistance after dilution	C-276 overlay for severe streams
Chemical reactor clad plate	carbon steel + 625 or C-276 clad	ERNiCrMo-3 / ERNiCrMo-4	clad side dictates filler; dilution control on the steel side	nickel-based electrode for repair
Dissimilar pipe joint, 316L to carbon steel	316L / carbon steel	ERNiCrMo-3	nickel filler tolerates dilution and differential expansion	E309L-16 where service is mild
High-temperature reformer outlet	800H / 600 / heat-resisting alloy	ERNiCr-3	niobium-stabilised deposit for creep service	ERNiCrMo-3 where corrosion dominates
Aircraft and gas turbine 718 fabrication	718	ERNiFeCr-2	must age with the parent; SAC controlled	ENiCrFe-3 for repair work
Wet chlorine and acid header	C-276	ERNiCrMo-4	molybdenum and tungsten for the most aggressive streams	625 where duty is less severe
Seawater pump and valve components	Monel 400 / K-500	ERNiCu-7 / ENiCu-7	nickel-copper weld metal for seawater and reducing duty	K-500 aged after welding for strength
HF alkylation unit repair	Monel 400	ENiCu-7	reducing-acid service; weld metal must match base	none conventional
Overlay on 9 % nickel steel LNG components	9 % Ni steel + nickel filler	ERNiCrMo-3 / ERNiCr-3	dilution tolerance and low-temperature toughness	nickel-based electrode
Repair of cast heat-resisting components	cast Ni-Cr alloys	ENiCrFe-3	ductile deposit on cast and aged parent	ENiCrMo-3 for corrosive duty

Table note: The applications are conventional industry selections based on the corrosion and high-temperature behaviour of the filler families in the earlier tables, and the final filler designation, the qualified dilution limit and the thermal cycle are those stated in the project welding procedure specification, qualified under ASME BPVC Section IX and using consumables classified to AWS A5.14 or A5.11 with parent metals to the ASTM standards listed in each case. Where more than one filler is technically acceptable, the deciding factor is usually the dilution the joint will see and the thermal cycle the component will receive, not the nominal alloy content of the wire.

Consumable	Form	Reference range, 2026, EXW Shanghai	Note
ERNiCrMo-3	bare wire, 1.2 / 1.6 / 2.4 mm	USD 45–75/kg	625-type wire; follows the LME nickel price
ERNiCrMo-4	bare wire, 1.2 / 1.6 / 2.4 mm	USD 55–90/kg	C-276 wire; tungsten and molybdenum content drive the band
ERNiCr-3	bare wire, 1.2 / 1.6 / 2.4 mm	USD 40–68/kg	600/800-type wire
ERNiFeCr-2	bare wire, 1.2 / 2.4 mm	USD 50–85/kg	Alloy 718 filler; ageing and tighter chemistry
ERNiCu-7	bare wire, 1.2 / 1.6 mm	USD 40–70/kg	Monel-type wire
ENiCrFe-3	covered electrode, 2.5–4.0 mm	USD 45–80/kg	600/800-type electrode
ENiCu-7	covered electrode, 3.2 / 4.0 mm	USD 45–80/kg	Monel-type electrode
ENiCrMo-3	covered electrode, 3.2 / 4.0 mm	USD 55–90/kg	625-type electrode for repair and root passes
625 overlay, in position	wire or strip, clad service	quotation by area, layer and dilution requirement	first-layer iron control governs the price

Table note: Reference range only, 2026, EXW Shanghai, USD/kg, indicative and not a quotation; nickel alloy welding consumables are priced from the alloying content and move with the LME nickel price and the molybdenum and tungsten markets, so firm prices are valid only for the delivery period quoted. Actual prices depend on diameter, spool or pack size, classification, lot certification, the standard set required (AWS A5.14 or A5.11, GB/T 15620 or GB/T 13814, JIS Z 3334, DIN 1736, GOST 2246 as applicable), the inspection documents to EN 10204 and the delivery terms. Where a consumable is supplied for code work, the price includes the lot-specific certification and the traceability to the heat, which is part of what the standard set is buying.

Two commercial points are worth stating. First, welding consumables are a small fraction of the cost of a nickel alloy fabrication and a large fraction of its risk, so the decision should be made on the qualified procedure rather than on the price per kilogram; a cheaper wire that dilutes differently or ages differently can cost an entire component. Second, a consumable that carries the complete standard set — AWS classification, the equivalent GB, JIS, DIN or EN and GOST designations, EN 10204 documentation and lot traceability — is worth a premium over one that carries only a headline classification, because the traceability is what allows the qualified procedure to be defended at the point of inspection. Our contact page takes the process data and the joint details and returns a consumable and procedure recommendation with the standard set and documents stated explicitly.

Standard Index

Standard	Title / scope	Covers	Form
AWS A5.14 / ASME SFA-5.14	Nickel and nickel alloy bare welding electrodes and rods	composition + form	wire, rod
AWS A5.11 / ASME SFA-5.11	Nickel and nickel alloy covered electrodes for SMAW	composition + coating	covered electrode
AWS A5.4 / ASME SFA-5.4	Stainless steel covered electrodes for SMAW	composition + coating	covered electrode
ASME BPVC Section IX	Welding, brazing and fusing qualifications	procedure + personnel	WPS / PQR / WPQ
ASME BPVC Section IIC	Welding rods, electrodes and filler metals	code adoption of AWS classifications	filler metals
ASME BPVC Section V	Nondestructive examination	inspection methods	test method
ISO 18274	Welding consumables — wire, strip and rod for nickel and nickel alloys	classification	wire, rod
ISO 14171 / ISO 14343	Wire electrodes for non-alloy/fine-grain steels; for stainless steels	classification	wire
DIN 1736	Welding consumables — nickel and nickel alloys	classification	wire, electrode
EN 10204	Metallic products — types of inspection documents (2.2, 3.1, 3.2)	inspection documents	all forms
GB/T 15620	Nickel and nickel alloy welding wire	classification	wire
GB/T 13814	Nickel and nickel alloy covered welding electrodes	classification	electrode
GB/T 14992	Classification and designation of superalloys and intermetallics	grade designation	all forms (待核 — confirm current edition)
JIS Z 3334	Nickel and nickel alloy welding wire and rod	classification	wire, rod
JIS G 4901	Corrosion-resistant and heat-resistant superalloy bars	parent metal	bar
GOST 2246	Welding wire — general specification	classification	wire
ASTM B443	Nickel-chromium-molybdenum-columbium alloy (N06625) plate, sheet and strip	parent metal	plate, sheet
ASTM B575	Low-carbon nickel-molybdenum-chromium alloy (N10276) plate, sheet and strip	parent metal	plate, sheet
ASTM B637	Precipitation-hardening nickel alloy bars, forgings and forging stock (718, 706)	parent metal	bar, forging
ASTM B164	Nickel-copper alloy (N04400) rod and bar	parent metal	bar, rod
ASTM B865	Nickel-copper-aluminium alloy (N05500) rod, bar and wire	parent metal	bar, wire

Table note: Standards are listed by number and scope; where an edition year is not quoted the latest edition applies and the controlling edition is the one named in the purchase order or the project specification. The consumable classification standards (AWS A5.14, A5.11, A5.4 and their ASME SFA equivalents, ISO 18274, DIN 1736, GB/T 15620, GB/T 13814, JIS Z 3334, GOST 2246) define the deposited chemistry and the supplied form, while the parent metal product standards define what the filler must be compatible with. AMS product specifications are also quoted for some high-temperature nickel welding wire; the correct AMS number should be verified against the current AMS index before it is written into a purchase order (待核). Conformance is normally evidenced by an EN 10204 3.1 certificate that identifies the heat, or an EN 10204 3.2 certificate where a third-party inspection is required, and the knowledge base explains the certificate types.

FAQ

Q1: How do I choose a nickel alloy welding consumable for a given parent metal?

Start with the parent metal combination, then subtract the dilution. If both sides are the same nickel alloy, the matching filler is normally correct: ERNiCrMo-3 for Alloy 625, ERNiFeCr-2 for Alloy 718, ERNiCr-3 for 600 and 800 series alloys, ERNiCrMo-4 for C-276, and ERNiCu-7 for Monel 400 or K-500. If the two sides differ, match the more highly alloyed side, because the lower-alloyed side contributes iron or chromium dilution rather than corrosion resistance. Then check the dilution the joint will actually see: a butt joint in 625 plate sees far less dilution than a first-layer overlay on carbon steel, and the same filler can be acceptable in the first case and marginal in the second. Finally, check the thermal cycle — interpass temperature, heat input and any post-weld heat treatment — because a filler that is correct in composition can still fail if it is held in the wrong temperature range. Hangbo Alloy reviews each enquiry against the parent metals, the process and the required standard set rather than quoting a wire on the grade name alone.

Q2: What is the difference between AWS A5.14 and AWS A5.11?

AWS A5.14 classifies bare nickel and nickel alloy welding electrodes and rods — the wire and cut-length products used for gas tungsten arc, gas metal arc and submerged arc welding. Its designations carry the ER prefix, as in ERNiCrMo-3 and ERNiCr-3. AWS A5.11 classifies covered nickel and nickel alloy electrodes for shielded metal arc welding, the manual process, and its designations carry the E prefix, as in ENiCrFe-3 and ENiCu-7. The two are not interchangeable in a qualified procedure: the flux coating changes the arc atmosphere and the recovery of reactive elements such as titanium and niobium, so the deposited chemistry from a covered electrode differs from that of the nominally similar wire. Where a procedure is qualified with wire, using the covered electrode without requalification is a nonconformance. Most nickel fabrications need both, because the root and fill may be welded by one process and the repair by another.

Q3: Why does dilution matter so much in overlay and dissimilar welding?

Because the weld metal that forms is not the filler metal — it is a mixture of filler and melted parent metal, and the mixture is what resists corrosion. On a carbon steel or low-alloy steel substrate, the first layer of a nickel alloy overlay can carry 15–30 % iron depending on the process and technique, and iron dilutes the chromium, molybdenum and nickel that provide the corrosion resistance. Once those elements fall below the threshold that sustains a passive film, the overlay stops protecting the substrate. The control measures are the low-dilution processes, stringer rather than heavy weave beads, controlled current and travel speed, a low interpass temperature and enough passes that the required chemistry is achieved at the depth the process stream will see. The acceptance criterion is written in terms of iron and of the alloying elements at a specified depth, and it is verified on a coupon welded with the production procedure rather than assumed from the wire certificate.

Q4: How is Hastelloy C-276 welding different from welding 625?

C-276 is less tolerant of heat than 625, and the difference is central to procedure design. The C-276 weld metal precipitates secondary phases — the mu and P phases — between roughly 600 °C and 1000 °C, and the loss of corrosion resistance and ductility that results is exactly the property the alloy was chosen for. The controls are a low heat input, a tightly limited interpass temperature, usually around 100 °C, the minimum number of passes consistent with the joint, and the avoidance of post-weld heat treatment unless it is specifically required and qualified. Where PWHT cannot be avoided it takes the form of a solution anneal with a rapid quench, which is a different operation from the stress relief used on carbon steel. Filler selection is also different: C-276 is welded with ERNiCrMo-4 or ENiCrMo-4, a tungsten-bearing filler with about 16 % molybdenum, and substituting ERNiCrMo-3 by mistake removes several percent of molybdenum from the deposit. Our Hastelloy range covers the plate, bar and matching wire.

Q5: How do I prevent strain-age cracking when welding Alloy 718?

Strain-age cracking occurs during the ageing cycle after welding, when the precipitation reaction starts while residual welding stress is still high and the material can accommodate only limited strain. Prevention is a combination of design and procedure. Minimise restraint in the joint, because a highly restrained joint cannot relieve the strain as it ages. Control the weld thermal cycle so that the heat-affected zone is not left in the most crack-sensitive condition, and avoid preheat, which increases the time at temperature and the strain. Control the heating rate into the ageing temperature so that the component is not shocked through the sensitive range, and in many cases use a solution anneal followed by ageing rather than ageing directly after welding. Inspect after heat treatment rather than before, because the cracking happens in the furnace and will not be present in the as-welded part. The procedure should be qualified to ASME BPVC Section IX with the ageing cycle included.

Q6: What shielding gas should be used for nickel alloy welding?

Argon is the default for gas tungsten arc and gas metal arc welding, giving a stable arc and a clean pool. Argon-helium mixtures are used where more heat and better wetting are wanted — heavier sections, faster overlay, more fluid pool — but helium raises the arc temperature and tends to increase dilution, which then has to be controlled by technique. Argon-hydrogen mixtures improve wetting and reduce surface oxide and are used mainly on austenitic materials; a hydrogen addition of up to about 5 % is the customary limit, and it should not be used on the copper-bearing nickel fillers or where the alloy is sensitive to hydrogen pickup, because it can contribute to porosity. For the more reactive alloys, backing and trailing shields protect the hot metal from air until it cools. Regardless of mixture, the flow rate must be adequate to exclude air without being so high that turbulence draws air into the plume, and the gas must be dry, with a low dew point, because moisture is a porosity source rather than a lubricant.

Q7: Is post-weld heat treatment required after welding nickel alloys?

Usually not, and in some cases it should be avoided. Nickel alloys are austenitic and do not need the post-weld heat treatment that carbon and low-alloy steels need to avoid hydrogen cracking. For the solid-solution alloys, PWHT is sometimes specified for stress relief in a particular service, but it is a service-driven decision rather than a routine one. For the nickel-chromium-molybdenum family, and especially for C-276, exposure in the 600–1000 °C range precipitates phases that reduce corrosion resistance, so PWHT should be avoided unless it is required and the procedure is qualified to demonstrate that the properties are met after the treatment. Where PWHT is unavoidable for the C-276 system, it takes the form of a solution anneal with a rapid quench. For the precipitation-hardening alloys such as 718 and Monel K-500, the post-weld operation is an ageing treatment that is part of the design, and it must be included in the qualified procedure.

Q8: What causes porosity in nickel alloy welds and how is it fixed?

Porosity in nickel alloy welding usually comes from gas contamination rather than from the filler itself. The sources are moisture on the joint faces or in the flux, oil, paint, marking fluid or machining coolant residue on the edges, inadequate shielding gas coverage in a deep groove or at the start and stop of a pass, wet or incorrectly stored electrodes, and air drawn in by excessive gas flow or by a draughty work area. Nickel alloys, and particularly the copper-bearing fillers, are more sensitive than steel because the weld pool is more viscous and releases gas more slowly. The fixes are procedural and simple to state: clean the joint immediately before welding and keep it clean, store electrodes in a controlled oven and use them within the specified exposure time, set the gas flow rate and nozzle size for the joint configuration, use a backing or trailing shield where the geometry demands it, and verify the gas quality. Porosity is normally detected by radiography, which should be part of the inspection plan for critical nickel joints.

Q9: Can nickel alloy filler be used to join stainless steel to carbon steel?

Yes, and it is a common and sound choice for corrosive service. A nickel-based filler such as ERNiCrMo-3 is often preferred over an austenitic stainless filler for a joint between 316L and carbon steel because the nickel weld metal tolerates more dilution before its properties fall below the acceptance line, and because its thermal expansion sits between the austenitic and the ferritic side and reduces the residual stress that drives cracking. The carbon steel side contributes iron to the weld metal, so the dilution must be calculated and the deposit chemistry checked where corrosion resistance is the reason for the joint. The alternative, a stainless filler such as E309L-16, is acceptable where the service is mild and where the higher ferrite content that helps resist hot cracking is an advantage. Either way the joint should be qualified to ASME BPVC Section IX with mechanical testing of the joint, not of the parent metals alone.

Q10: Why is Monel K-500 harder to weld than Monel 400?

Because it is age hardened after welding, and because its titanium and aluminium additions are reactive. Monel 400 is welded with ERNiCu-7 or ENiCu-7 and requires no subsequent heat treatment, so the weld metal chemistry is essentially fixed by the filler and the dilution. Monel K-500 is welded and then aged at around 595–620 °C to develop its strength, which means the weld must also respond to the ageing treatment, and the titanium and niobium additions that drive that response can be lost to oxidation in the arc or to overheating. Shield quality, arc length and heat input therefore control the composition of the deposit, and the aged weld metal chemistry should be confirmed rather than assumed. A K-500 fabrication also cannot be locally aged after welding without considering the parent metal, so the component is usually aged as a whole, and the welding procedure must be qualified with the ageing cycle included.

Q11: What documentation should accompany a nickel alloy welding consumable?

At minimum, the supplier should provide an inspection document to EN 10204 that identifies the heat or lot, the classification to the applicable standard — AWS A5.14 for wire, AWS A5.11 for covered electrodes — and the deposited chemistry and mechanical properties where the specification requires them. For code work, an EN 10204 3.1 certificate is the normal requirement, and an EN 10204 3.2 certificate is used where a third-party inspector is to witness the testing. The certificate should also state any equivalent designations under the standards named in the project specification, such as GB/T 15620 or GB/T 13814, JIS Z 3334, DIN 1736 or GOST 2246, because a lot that satisfies one classification system may not be certified against another. Traceability from the certificate to the pack, spool or electrode batch on site is part of the requirement, and it is what allows the qualified welding procedure to be defended at final inspection. Ask for the full standard set rather than a headline classification.

Conclusion and Selection Rules

Nickel alloy welding consumables selection comes down to four questions asked in order. What are the parent metals, and which of them is the more highly alloyed? What dilution will the joint see, and will the deposit composition still meet the requirement at the depth the service exposes? What thermal cycle will the component receive through welding, interpass and any post-weld heat treatment? And what procedure qualification and documentation route does the project require? Answering those questions selects the filler, sets the parameters and defines the verification, in that order.

The matching rules themselves are compact. ERNiCrMo-3 covers Alloy 625, Alloy 718, dissimilar steel joints and overlay cladding, and it is the default nickel-based filler for corrosive service because it tolerates dilution and carries the molybdenum and niobium the service needs. ERNiCrMo-4 is reserved for the C-276 and C-22 family, where the tungsten-bearing, high-molybdenum deposit is essential and the thermal cycle must be held tight. ERNiCr-3 covers the 600 and 800 series and their dissimilar joints, and it should not be asked to do corrosion duty that depends on molybdenum. ERNiCrFe-3-type electrodes cover the same alloys in manual work while remembering that the deposited chemistry differs from the wire. ERNiCu-7 and ENiCu-7 cover Monel 400 and Monel K-500, with K-500 requiring the ageing cycle to be included in the qualification. Around those matches sit the process controls — dilution management on overlays, low heat input and interpass limits on C-276 and 718, heat input and shielding discipline on the copper-bearing fillers — and the documentation that ties the lot to the qualified procedure.

Shanghai Hangbo Alloy Group Co., Ltd. supplies the parent metals and the matching welding consumables as a single package: Alloy 625, Alloy 718, Hastelloy C-276, Inconel 600 and 601, Incoloy 800H, Monel 400 and Monel K-500 in bar, plate, sheet, tube, pipe and forgings, together with ERNiCrMo-3, ERNiCrMo-4, ERNiCr-3, ERNiFeCr-2 and ERNiCu-7 bare wire and the matching covered electrodes, certified to AWS A5.14 or A5.11 with mill test certification to EN 10204 3.1, chemistry verification by XRF, and third-party inspection by SGS, BV or TUV. Send the parent metals, the joint details, the process and the standard set you need through our contact page and we will recommend the consumable, the deposition strategy and the verification scope, and quote the material and the filler together so that the certificate chain matches.

Contact & Complete Product Range

Shanghai Hangbo Alloy Group Co., Ltd. - China Supplier

Email: sales@hangboalloy.com | WhatsApp (Lisa): +86 13611656360 | www.nickel-alloy.com

All Grades

Ni: NI200-N6 | Monel: 400-502, K-500, R-405 | Inconel: 600-740H, X-750, 725 | Incoloy: 800-27-7MO | Hastelloy: C-276-HYBRID-BC1, N | Super Austenitic: 904L-AL-6XN | Chromium-Rich: Alloy 33 | High-Strength Stainless: Nitronic 50/60, PH13-8Mo | Chlorination: Alloy 45 | Nimonic: 75-263 | Haynes: 25-HR-160 | RA: 330/333 | Precision: 1J22-4J45 | High-Strength: 18Ni250-AerMet100 | Heating: Cr20Ni80/60 | Specialty: Alloy 20-602CA

Welding Consumables: ERNiCrMo-3 | ERNiCrMo-4 | ERNiCr-3 | ERNiFeCr-2 | ERNiCu-7 | ENiCrFe-3 | ENiCu-7 | ENiCrMo-3

Product Forms: Bars(6-500mm) | Tubes(OD 6-610mm) | Plates(0.1-100mm) | Forgings | Welded Pipes | Fittings | Wire(0.05-10mm) | Strip(0.02-4.0mm)

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