Table of Contents
Ferro nickel welding rods are specialized consumables used for welding cast iron, nickel alloys, and dissimilar metals. These rods typically contain a high percentage of nickel (up to 99%) and are essential in maintenance and repair welding due to their excellent crack resistance, machinability, and weldability. This article provides a comprehensive overview of ferro nickel welding rods, their types, pricing, composition, applications, and suppliers—along with detailed tables for comparison and answers to commonly asked questions at the end.
What Are Ferro Nickel Welding Rods?
Ferro nickel welding rods are electrodes designed for manual arc welding (SMAW) and often contain a mixture of nickel and iron. They are widely used for welding cast iron and for joining cast iron to steel. The presence of nickel improves the ductility and crack resistance of the weld metal, while iron increases strength and cost efficiency.
Common Types of Ferro Nickel Welding Rods
| Type | Nickel Content | Typical Application | AWS Classification |
|---|---|---|---|
| Nickel 99% | 99% | Precision welding of gray cast iron | ENi-CI (AWS A5.15) |
| Nickel 55% | 55% | General purpose cast iron welding | ENiFe-CI (AWS A5.15) |
| Ferro Nickel (Fe-Ni) | 45–60% | Joining cast iron to carbon steel | ENiFe-CI |
Chemical Composition of Common Rods
| Grade | Nickel (%) | Iron (%) | Carbon (%) | Other Elements |
|---|---|---|---|---|
| ENi-CI | ~99 | <1 | Low | Trace elements |
| ENiFe-CI | ~55 | ~45 | Low | Mn, Si |
Ferro Nickel Welding Rod Sizes and Packaging
| Diameter (mm) | Length (mm) | Weight per Box (kg) | Packaging Type |
|---|---|---|---|
| 2.5 | 350 | 5 | Carton Box |
| 3.2 | 350 | 5 | Carton Box |
| 4.0 | 400 | 5 | Carton Box |
Current Price of Ferro Nickel Welding Rods
| Type | Diameter | Price (USD/kg) | Typical Use |
|---|---|---|---|
| Nickel 99% | 3.2 mm | $65 – $90 | Precision gray cast iron repair |
| Nickel 55% | 3.2 mm | $35 – $60 | General purpose welding |
| Ferro Nickel | 3.2 mm | $30 – $55 | Joining cast iron to steel |
Key Factors Affecting Price
- Nickel Content: Higher nickel increases cost significantly.
- Rod Purity: Premium rods with tighter composition tolerances cost more.
- Manufacturer Origin: European and US rods are more expensive than those made in Asia.
- Order Volume: Bulk purchases reduce per-kg cost.
- Certifications: Rods conforming to AWS or ISO standards have a price premium.
Major Suppliers of Ferro Nickel Welding Rods
| Supplier | Country | Product Range |
|---|---|---|
| Lincoln Electric | USA | ENiFe-CI, ENi-CI, nickel alloy rods |
| ESAB | Sweden | Special welding electrodes |
| Weldwell | New Zealand | Cast iron repair rods |
| Böhler | Austria | Ferro-nickel and dissimilar metal rods |
| Weldtech Alloys | India | Cost-effective Fe-Ni rods |
Applications of Ferro Nickel Welding Rods
- Repair of engine blocks, housings, pump bodies (cast iron)
- Welding cast iron to steel structures
- Joining dissimilar metals in maintenance welding
- Rebuilding worn cast components
Buying Tips
- Choose the correct nickel content based on application type.
- Request mill certificates and test results from supplier.
- Compare suppliers across regions for pricing advantage.
- Ensure the rod is compatible with your welding equipment and process.
Related Questions
1. What is the best welding rod for cast iron repair?
Nickel 99% rods (ENi-CI) are the best choice for precise and crack-free welds on gray cast iron due to their high ductility.
2. Why are nickel-based rods more expensive?
Nickel is a costly raw material, and rods with high nickel content offer superior properties like machinability and corrosion resistance, which increase production cost.
3. Can I use ferro nickel rods for welding steel?
Yes, ferro nickel rods are suitable for welding cast iron to steel, offering excellent compatibility and reduced risk of cracking.