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At Ronsco, a leading supplier of stainless steel plate and alloy materials, we understand the increasing demand for reliable welding solutions between stainless steel and nickel-based alloys—especially in fields like petrochemical, aerospace, and nuclear energy. This article explores the core properties of both materials, welding challenges, advanced joining techniques, and essential quality control practices to help engineers achieve stable and high-quality joints.
Primary Composition: Iron-Chromium-Nickel (Fe-Cr-Ni) alloy system
Key Features:
Corrosion Resistance: Passive film forms with Cr content ≥16%
Mechanical Strength: Tensile strength ≥515 MPa; elongation ≥40%
Common Applications:
Food-grade machinery
Medical equipment
Chemical processing systems
Composition: Nickel ≥50%, with Mo, Cr, Nb as strengthening elements
Key Advantages:
High-Temperature Performance: Maintains ≥70% of room-temp strength at 800°C
Corrosion Resistance: Excellent resistance to harsh acids like H₂SO₄ and HF
Typical Applications:
Jet engine parts
Petrochemical reactors
Nuclear-grade pressure vessels
Thermal Expansion Mismatch: Nickel alloys have 15–20% lower thermal expansion than stainless steel
Phase Transformation Range: Difference of 200–300°C
Oxidation Behavior: Cr₂O₃ (dense) vs. NiO (porous) affects joint surface stability
Hot Cracking Sensitivity: Ni-Al/Mg systems may form liquation cracks
Element Segregation: Fe-Ni-Cr alloys tend to exhibit dendritic segregation
Filler Metal Recommendation: ERNiCrMo-3 (per AWS A5.14)
Key Process Parameters:
Current Type: DCEN (Direct Current Electrode Negative)
Heat Input: 8–12 kJ/cm
Interpass Temperature: ≤150°C
This technique helps bridge thermal and metallurgical differences between the two metals.
Parameter | Electron Beam Welding | Laser Welding |
---|---|---|
Vacuum Requirement (Pa) | 10⁻³ to 10⁻⁴ | Ambient or localized |
Maximum Penetration (mm) | ≤50 | ≤12 |
Welding Distortion (%) | 0.1–0.3 | 0.3–0.8 |
High-energy beam welding is ideal for critical applications requiring low distortion and deep penetration.
Groove Finish: Machining + electropolishing (Ra ≤1.6 μm)
Cleaning Procedure:
Ultrasonic cleaning in acetone (15 minutes)
Alcohol degreasing for surface purity
Shielding Gas: Argon + 2% H₂ (dew point ≤–60°C)
Welding Sequence:
Weld the nickel alloy transition layer
Then weld the stainless steel side
Solution Annealing: 1100°C × 1 hour followed by water quenching
Stress Relief Annealing: 650°C × 2 hours, air-cooled
Radiographic Testing: Compliant with ASME Section V, Class B
Corrosion Testing: Passes ASTM G28 Method A
At Ronsco, we not only supply high-quality stainless steel plates and nickel-based alloys, but we also provide tailored welding recommendations, technical documentation, and machining services. Our materials are widely used in marine engineering, pressure vessels, energy systems, and aerospace-grade fabrication.
To explore product specifications or get welding support, visit:
👉 www.ronscoplate.com
Need help selecting filler metals, defining process parameters, or requesting data sheets?
📧 Email us at: info@ronscoplate.com
📞 Or leave a message directly via our Contact Page
✅ Stay tuned to Ronsco News for more technical guides and material innovations in the stainless and nickel alloy industry.