AWS Class ERCuAl-A2 MIG/TIG: Composition, Properties, and Uses
Imagine a filler metal that not only excels in welding but also offers superior corrosion resistance and high tensile strength.…
When it comes to welding super duplex stainless steel, one name stands out among the rest: AWS Class ER2594. This filler metal is renowned for its exceptional strength and corrosion resistance, making it indispensable in demanding applications such as offshore oil rigs and chemical processing plants. But what exactly makes AWS Class ER2594 so special? From its intricate chemical composition to its impressive mechanical properties, this article delves into the finer details that set it apart. How does it perform under extreme conditions, and what are its most common uses? Let’s explore the fascinating world of AWS Class ER2594 and discover why it’s the preferred choice for welding professionals worldwide.
AWS Class ER2594 MIG/TIG filler metal is a top-tier welding wire engineered for exceptional performance with duplex and super duplex stainless steel alloys. This specialized filler metal is renowned for its excellent mechanical properties and superior resistance to various forms of corrosion, making it an ideal choice for demanding applications in industries such as oil and gas, chemical processing, and power generation.
ER2594 filler metal boasts a balanced composition of chromium (24-27%) for corrosion resistance, nickel (8-10.5%) for added toughness, molybdenum (2.5-4.5%) for pitting and crevice corrosion resistance, and nitrogen (0.20-0.30%) to optimize mechanical properties. Additionally, it contains smaller amounts of manganese, silicon, phosphorus, sulfur, copper, and tungsten to further enhance its performance.
The mechanical properties of AWS Class ER2594 filler metal ensure robust performance: a tensile strength of around 123,000 psi (850 MPa), yield strength of approximately 94,000 psi (650 MPa), and 28% elongation. These properties ensure that the welded joints can withstand high stress and provide long-term reliability.
ER2594 filler metal is ideal for welding alloys such as UNS S32550, J93370, J03372, as well as carbon steels and other duplex stainless steels like UNS S32205 and J92250. This versatility makes it a valuable choice for different welding scenarios.
Due to its outstanding properties, AWS Class ER2594 filler metal is extensively used in several industries:
These applications benefit from the filler metal’s high tensile strength, excellent corrosion resistance, and overall durability.
AWS Class ER2594 is classified under AWS A5.9 and is available in various forms, including MIG spools, TIG cut lengths, reels, and coils. The filler metal is also available in standard TIG straight lengths of 36” (914 mm) or 39” (1000 mm), with other lengths available upon request.
Products may include ink jet printing for easy identification along the entire length of the electrode. Additionally, a Q2 Lot® certificate, detailing the actual wire composition and calculated ferrite number (FN), is available online. ER2594 filler metal provides matching chemistry and mechanical properties to wrought super duplex alloys such as 2507 and Zeron 100, as well as superduplex casting alloys (ASTM A890).
The AWS Class ER2594 MIG/TIG filler metal is carefully designed with a precise chemical composition to ensure optimal performance and suitability for demanding applications. The key elements include:
ER2594 filler metal offers outstanding resistance to stress corrosion cracking (SCC) and pitting, thanks to its high chromium, molybdenum, and nitrogen content. This makes it ideal for chloride-rich and harsh marine environments.
Key physical properties include a specific gravity of 7.8 and a melting range of 1350°C to 1420°C. These characteristics contribute to its flexibility and toughness.
ER2594 filler metal boasts impressive mechanical properties, including a tensile strength of 123,000 psi (850 MPa), a yield strength of 94,000 psi (650 MPa), and an elongation of 28%. Its impact toughness is typically 50 J (37 ft-lbf) at -196°C (-321°F), and it maintains a hardness of HRB 95-100, HRC 32-35.
ER2594 filler metal is known for its flexibility, toughness, and heat resistance, ensuring reliable performance under various welding conditions.
The AWS Class ER2594 MIG/TIG filler metal is known for its outstanding tensile strength, which is crucial for materials used in high-stress environments. The tensile strength of this filler metal is approximately 123,000 psi (850 MPa), although some sources indicate a minimum value of 100,000 psi (690 MPa). This high tensile strength ensures that the welded joints can withstand substantial loads without failure, making it suitable for applications requiring robust and durable welds.
Yield strength measures the stress level at which a material begins to permanently deform. AWS Class ER2594 filler metal has a yield strength of around 94,000 psi (650 MPa), with some sources specifying a minimum of 80,000 psi (550 MPa). This high yield strength ensures that the material can sustain significant stress before permanent deformation occurs, providing reliability and stability in demanding applications.
The elongation percentage of AWS Class ER2594 filler metal is around 28%, meaning it can stretch significantly before breaking. This high elongation enhances the toughness and flexibility of the weld.
Impact toughness indicates how well a material can absorb energy during sudden impacts, essential for applications with dynamic loads. AWS Class ER2594 filler metal demonstrates impressive impact toughness, typically 50 J (37 ft-lbf) at -196°C (-321°F). This property ensures that the welds remain intact and functional even under extreme low-temperature conditions, making it suitable for cryogenic applications.
The hardness of AWS Class ER2594 MIG/TIG filler metal falls within the range of HRB 95-100 and HRC 32-35. Hardness is an indicator of a material’s resistance to deformation and wear. The specified hardness range ensures that the filler metal can maintain its shape and structural integrity under various mechanical stresses, contributing to the longevity and durability of the welded joints.
AWS Class ER2594 filler metal is designed to perform exceptionally well in aggressive environments, particularly those containing chlorides, sulfides, and hydrogen sulfides. Its high resistance to stress corrosion cracking (SCC) and pitting corrosion makes it ideal for applications in harsh marine and chemical processing environments. The combination of its chemical composition and mechanical properties ensures that it can withstand the challenging conditions often encountered in these industries.
This filler metal also offers excellent heat resistance, withstanding temperatures from 1350°C to 1420°C without losing structural integrity. This makes it suitable for applications involving high thermal loads, such as those found in power generation and industrial processing equipment.
Overall, the mechanical properties of AWS Class ER2594 MIG/TIG filler metal make it a reliable choice for demanding industrial applications. Its high tensile and yield strength, significant elongation, excellent impact toughness, and resistance to deformation and wear ensure that it can deliver long-lasting and robust performance in a variety of challenging environments.
The AWS Class ER2594 MIG/TIG welding wire is a versatile tool prized across numerous industries for its high strength, toughness, and excellent resistance to corrosion. Here are some of the primary industrial sectors where this filler metal is utilized:
In the oil and gas sector, AWS Class ER2594 is vital for fabricating and repairing offshore equipment. Its superior resistance to corrosion in harsh environments, including those with chlorides and sulfides, makes it ideal for pipelines, pressure vessels, and other essential infrastructure.
Chemical processing facilities expose equipment to harsh chemicals and high temperatures. AWS Class ER2594 is used in manufacturing and maintaining this equipment due to its strong corrosion resistance and durability under extreme conditions.
The marine industry depends on materials that endure constant exposure to seawater and corrosive environments. AWS Class ER2594 is essential in shipbuilding, repairs, and other marine applications, providing durability and long-lasting performance in tough conditions.
Desalination plants require materials that can endure high levels of chlorides and sulfides. AWS Class ER2594 is used in the construction and maintenance of these plants, providing reliable performance and resistance to pitting and stress corrosion cracking.
In the pulp and paper industry, heat exchangers and other equipment must resist corrosion to ensure longevity and efficiency. AWS Class ER2594 filler metal is applied in the fabrication of such equipment, ensuring they can withstand the corrosive processes involved in pulp and paper production.
AWS Class ER2594 MIG/TIG welding wire is versatile and tailored for specific uses requiring unique mechanical and chemical properties.
Designed specifically for welding super-duplex stainless steels such as UNS S32550, J93370, and J03372, AWS Class ER2594 provides excellent corrosion resistance and mechanical properties. This makes it ideal for critical applications where material integrity is paramount.
The filler metal is extensively used in pipeline fabrication operations. Its high strength, toughness, and resistance to stress corrosion cracking and pitting corrosion make it suitable for pipelines that transport corrosive substances under high pressure.
In the transportation sector, AWS Class ER2594 is used in the manufacturing and repair of vehicles and machinery that operate in varied environmental conditions. Its ability to maintain strength and resist corrosion ensures the longevity and reliability of transportation equipment.
AWS Class ER2594 MIG/TIG welding wire is a versatile and reliable filler metal that meets the stringent demands of various industrial applications. Its superior properties make it an excellent choice for sectors such as oil and gas, chemical processing, marine engineering, desalination, and pulp and paper, as well as for specific uses like welding super-duplex stainless steels and pipeline fabrication.
Maintaining appropriate temperatures during welding is crucial for achieving optimal results with AWS Class ER2594 MIG/TIG filler metal. The interpass temperature should not exceed 300°F (149°C). This ensures that the weld metal and the base material retain their mechanical properties and resistance to corrosion, preventing weaker structures from forming.
Proper heat input control is essential to prevent the formation of structures that can weaken the weld. To calculate heat input, follow these steps:
The recommended heat input range is between 10-30 kJ/in, ensuring a balanced microstructure with the desired mechanical properties.
Post-weld heat treatment (PWHT) is not generally required for AWS Class ER2594 MIG/TIG filler metal. However, if needed for your specific project, follow the guidelines provided by the manufacturer or relevant standards to ensure the weld retains its properties.
By adhering to these welding parameters and guidelines, professionals can achieve high-quality, reliable welds with AWS Class ER2594 MIG/TIG filler metal, suitable for demanding industrial applications.
Ensuring safety is paramount when using AWS Class ER2594 MIG/TIG filler metals to protect both the welder and the workspace. Adhering to the following guidelines will help maintain a safe environment and achieve optimal welding results.
Good ventilation keeps the air clean and reduces the risk of breathing in harmful metal fumes. Ensure that your workspace is equipped with effective ventilation systems to maintain a healthy atmosphere.
Wear a welding helmet, heat-resistant gloves, and flame-resistant clothing to protect yourself from radiation, burns, and sparks. These protective measures are essential to prevent injuries and ensure safe welding practices.
To achieve the best results with AWS Class ER2594, consider the following best practices:
By following these safety tips and best practices, you can create high-quality welds with AWS Class ER2594, ensuring both safety and top performance.
AWS Class ER2594 MIG/TIG filler metal meets multiple high-quality industry standards, making it ideal for various applications. Key standards include:
The precise chemical composition of AWS Class ER2594 ensures consistent performance, with Carbon (0.01-0.03%), Chromium (24.0-27.0%), Copper (0.10-1.5%), Iron (balance), Manganese (0.60-2.5%), Molybdenum (2.5-4.5%), Nickel (8.0-10.5%), Nitrogen (0.20-0.30%), Phosphorous (0.02-0.03%), Silicon (0.40-1.0%), Sulfur (0.001-0.02%), and Tungsten (1.0%).
AWS Class ER2594 filler metal is known for its strength and durability, with a tensile strength of 123,000 psi, yield strength of 94,000 psi, and 28% elongation.
This filler metal includes an additional 2-3% Nickel to enhance its mechanical properties and corrosion resistance. It is ideal for welding super duplex stainless steels like Type 2507 and Zeron 100, as well as ASTM A890, UNS S31260, S32750, S32760, and S32550. Suitable for process pipework, pumps, valves, and pressure vessels, it can also weld carbon and low alloy steels to duplex steels. The over-alloyed nitrogen content helps maintain the desired ferrite/austenite ratio, providing superior resistance to stress corrosion cracking and pitting corrosion.
For welding, use MIG-DCEP or TIG-DCEN currents with diameters ranging from .023” to 1/8”. Shielding gas should be 100% Argon for TIG welding. Maintain heat input between 10,000 – 30,000 Joules/inch and keep the interpass temperature below 300°F (150°C).
Below are answers to some frequently asked questions:
The chemical composition of AWS Class ER2594 MIG/TIG filler metal includes Carbon (C) at 0.01%, Chromium (Cr) at 25.1%, Copper (Cu) at 0.10%, Iron (Fe) as the balance, Manganese (Mn) at 0.60%, Molybdenum (Mo) at 3.90%, Nickel (Ni) at 9.20%, Nitrogen (N) at 0.27%, Phosphorous (P) at 0.02%, Silicon (Si) at 0.40%, Sulfur (S) at 0.001%, and Tungsten (W) at 1.00%. This composition is tailored for welding super-duplex stainless steels, providing excellent corrosion resistance, especially in chloride-bearing environments.
The AWS Class ER2594 MIG/TIG filler metal, used for welding super duplex stainless steels, exhibits notable mechanical properties, including a tensile strength of approximately 123,000 psi (850 MPa) and a yield strength of 94,000 psi (650 MPa). It also has an elongation at break of 28%, which contributes to its ductility and robustness. These properties make it suitable for demanding applications, ensuring high performance and durability in industries like offshore and process pipework, as discussed earlier in the article.
AWS Class ER2594 MIG/TIG filler metal is typically used in industries requiring high strength and excellent corrosion resistance, such as the oil and gas sector for pipelines and pressure vessels, chemical and petrochemical plants for corrosive environments, and marine and offshore applications due to its high Pitting Resistance Equivalent Number (PREN). It is also suitable for welding super duplex stainless steels and in high-pressure, high-corrosion environments where its balanced duplex structure and high content of chromium, molybdenum, and nitrogen provide resistance to stress corrosion cracking and pitting.
The recommended welding parameters for AWS Class ER2594 MIG/TIG filler metal include using DCEP (Direct Current Electrode Positive) for MIG and DCEN (Direct Current Electrode Negative) for TIG processes. For MIG, use a current setting of 150-225 amps at 23-26 volts for 0.035” wire, 200-325 amps at 24-28 volts for 0.045” wire, and 300-350 amps at 24-27 volts for 1/16” wire, maintaining an arc length of 1/2”-3/4”. The heat input should be between 10,000 – 30,000 Joules/inch, with an inter-pass temperature not exceeding 300°F (149°C). Inert gas, typically argon, is recommended for shielding.
AWS Class ER2594 MIG/TIG filler metal complies with the AWS A5.9 and ASME SFA 5.9 standards, which specify the requirements for welding superduplex stainless steels. These standards ensure that the filler metal meets stringent criteria for chemical composition and mechanical properties, making it suitable for demanding applications such as power generation and offshore industries. The compliance with these standards guarantees that the filler metal provides high tensile and yield strength, excellent resistance to stress corrosion cracking, and optimal performance in challenging environments, as discussed earlier in the article.
When using AWS Class ER2594 MIG/TIG filler metal, ensure proper ventilation to avoid inhaling harmful fumes, and use appropriate personal protective equipment (PPE) such as welding helmets, gloves, and protective clothing. Keep the welding area free of flammable materials to prevent fires. Follow the manufacturer’s welding parameter recommendations, maintain interpass temperatures below 300°F (149°C), and control heat input. Preheat and conduct post-weld heat treatment as necessary, and handle filler metal wires carefully to avoid contamination. These precautions and best practices help ensure safe and effective welding operations.
