Unlocking the “Welding Code” of Pure Nickel Wire: Chengxin Alloy’s Breakthrough for High-Reliability Joints

In harsh environments characterized by high temperatures and corrosion, pure nickel wire has become an essential material due to its outstanding heat resistance, oxidation resistance, and electrical conductivity. However, its poor weldability has long challenged the industry—frequent issues such as oxidation, hot cracking, and weak joint strength have limited its application.

As a leading innovator in special alloy materials, Our company Jiangyin Chengxin Alloy Materials Co., Ltd. has successfully tackled the welding challenges of pure nickel wire through systematic research and process optimization, delivering high-reliability solutions for demanding industries.

Key Challenges in Pure Nickel Wire Welding

• Oxidation Barrier:
  Nickel rapidly reacts with oxygen at high temperatures, forming a dense NiO film that hinders wetting, resulting in poor fusion and porosity.
• Hot Cracking Sensitivity:
  Nickel’s high thermal expansion and residual stress during welding, combined with low-melting-point impurities (such as sulfur and phosphorus), significantly increase the risk of solidification cracking.
• Inconsistent Joint Performance:
  Traditional welding methods struggle to balance joint strength, electrical conductivity, and high-temperature durability, compromising long-term reliability.

Chengxin Alloy’s Innovative Solutions

Through material optimization, advanced welding techniques, and equipment upgrades, Chengxin Alloy has significantly enhanced the weldability and reliability of pure nickel wires:

1. Material Solutions: Ultra-Pure Nickel with Micro-Alloying

Use of 99.98% high-purity nickel wire, with strict control of S and P below 0.005% to reduce hot cracking tendency.

Introduction of rare earth elements (such as La, Ce) to refine grain structure, improving weld toughness (impact strength increased by over 30%).

2. Process Solutions: Precise Inert Gas Shielding

Pulsed TIG welding with dual-side argon protection: Pre-purging breaks the oxide film, pulsed current reduces heat input, ensuring dense welds with porosity <0.5%.

Laser-Assisted Brazing: For ultra-fine nickel wires (diameter <0.1mm), low-melting-point silver-based brazing alloys combined with laser heating achieve “zero deformation” joints.

3. Verified Performance: Joints Matching Base Metal

Tensile strength: ≥90% of base metal (measured ≥320 MPa)

Electrical conductivity retention: >95% of International Annealed Copper Standard (IACS)

High-temperature creep resistance: Service life improved by over 2 times at 1000°C.

Proven Applications in Demanding Industries

Our advanced welding solutions have been successfully applied in:

✅ New Energy:
Laser welding of nickel current collectors for power batteries, improving yield rates to 99.3%.

✅ Aerospace:
Brazing of nickel wire leads for engine sensors, passing thermal shock tests from -196°C to +800°C.

✅ Chemical Processing:
Welding of corrosion-resistant nickel wire heating elements for reactors, extending service life by 5 years.

Conclusion

The reliability of pure nickel wire joints defines the performance limits of end products. Through integrated research on material design, process optimization, and performance validation, Our company Chengxin Alloy has not only cracked the welding “code” of pure nickel but also pushed the boundaries of joint durability and stability.

We are committed to continuous innovation in special alloy joining technologies, delivering efficient and reliable material solutions for industries worldwide.

Contact us today or visit:
www.heatingalloywire.com
for customized welding solutions!