AWS A5.9 (wire) and A5.4 (electrode) · Super duplex wire, rod and stick electrode
ER2594 is a super duplex stainless steel filler metal carrying nominally 25 % chromium, 10 % nickel and 4 % molybdenum with controlled nitrogen, used for welding 2507, UNS S32750 and comparable super duplex grades whose pitting resistance equivalent reaches 40 or above, depositing weld metal at roughly 650 to 700 MPa yield with approximately 50 FN ferrite and impact energy to 170 J at −50 °C.
Price on request. POFIS is an ESAB Authorized Distributor & Service Centre in Abu Dhabi — quotations include confirmed lead time and delivery terms.
The designation
Reading the ER2594 / E2594 designation, left to right.
How it behaves
Super duplex reaches a pitting resistance equivalent of 40 or above, against 35 for standard 2205 duplex and roughly 24 to 26 for 316L. That step is what qualifies it for seawater systems, aggressive produced water, firewater and subsea applications where 2205 would eventually pit. It also carries higher strength again, which lets a designer reduce wall thickness in services where the alloy cost per kilogram is already high.
This is the error the page exists to prevent. Welding super duplex with standard duplex consumables leaves the weld with a lower PRE than the material either side of it, so the weld becomes the preferential corrosion site in exactly the service the parent was specified to survive. The joint will pass every mechanical and radiographic test and fail in service. Match the family: ER2594 and E2594 for super duplex, ER2209 and E2209 for 2205.
ESAB gives 2 to 15 kJ/cm for super and hyper duplex, against 5 to 25 kJ/cm for standard duplex, with 10 kJ/cm or less preferred on thin sheet — and an interpass ceiling of 150 °C against 250 °C for duplex. Both limits are narrower. The same two-sided risk applies: too little heat input leaves excess ferrite, too much allows sigma and other intermetallics to precipitate, and super duplex precipitates them more readily because it is more heavily alloyed.
Nitrogen counts three times as heavily as molybdenum in the PRE calculation, so on an alloy selected for its PRE, nitrogen lost from the root pool is a direct loss of the property the material was bought for. ESAB recommends pure nitrogen backing for duplex generally, and lists N2 among the shielding options for the super duplex TIG grade. On super duplex this is not a refinement — it is part of meeting the specification.
ESAB publishes approximately 50 FN for Exaton 25.10.4.L. Super duplex procedures specify a ferrite acceptance range and verify it, and the window is generally tighter than for 2205 because the consequences of imbalance are greater at this alloy level. Agree the method and limits with the client before welding — a weld outside the range is not reworkable into compliance.
What POFIS supplies
Every grade below carries the ER2594 / E2594 classification, which is why a WPS naming ER2594 / E2594 can be satisfied by any of them. They are not interchangeable in practice — the differences in current type, hydrogen level and impact toughness are what decide which one belongs on your job. Figures are the manufacturer's typical as-welded values.
| Grade | Classification | Yield | Tensile | Elong. | Impact (lowest published) |
|---|---|---|---|---|---|
| Exaton 25.10.4.L (GMAW) POFIS recommends | ER2594 (AWS A5.9) | 700 MPa | 880 MPa | 30 % | 170 J at −50 °C |
| Exaton 25.10.4.L (GTAW) | ER2594 (AWS A5.9) | 650 MPa | 850 MPa | 25 % | 150 J at −46 °C |
| OK Autrod 2509 | ER2594 (AWS A5.9) | 659 MPa | 832 MPa | 30 % | 129 J at −40 °C |
| OK 68.53 | E2594-16 (AWS A5.4) | — | — | — | — |
| OK 68.55 | E2594-15 (AWS A5.4) | — | — | — | — |
The strongest consumable here at 700 MPa yield and 880 MPa tensile, with 230 J at room temperature and 170 J at −50 °C, approximately 50 FN, in 0.8 mm to 1.6 mm. For most super duplex fabrication on a wire feeder.
The TIG form, at 650 MPa yield and 850 MPa tensile with 210 J at room temperature and 150 J at −46 °C. ESAB lists I1, I3 and N2 shielding — the nitrogen-bearing option is what a super duplex procedure normally requires.
The standard super duplex MIG wire in 1.0 and 1.2 mm, at 659 MPa yield and 832 MPa tensile with 159 J at room temperature and 129 J at −40 °C.
The rutile super duplex stick electrode. Runs more easily and gives a better bead than the basic grade. Re-dried at 250 °C for two hours.
The basic super duplex stick electrode, with tougher weld metal than the rutile grade. The starting point where a super duplex procedure sets impact requirements, which it usually does. Re-dried at 250 °C for two hours.
Diameters are listed from the manufacturer's deposition data. Ordering part numbers and pack sizes are confirmed with your quotation — send the grade and diameters you need to weldiv@pofis.ae.
Specifying
Exaton 25.10.4.L is the strongest consumable on this page at 700 MPa yield and 880 MPa tensile, with 230 J at room temperature and 170 J at −50 °C, approximately 50 FN, in 0.8 mm to 1.6 mm under M12 shielding. For most super duplex fabrication on a wire feeder this is the grade to quote.
Exaton 25.10.4.L in TIG form gives 650 MPa yield and 850 MPa tensile with 210 J at room temperature, 170 J at −40 °C and 150 J at −46 °C. ESAB lists I1, I3 and N2 shielding — the nitrogen-bearing option being what a super duplex procedure normally requires. For a root that must meet both an impact requirement and a PRE criterion, this is the starting point.
OK Autrod 2509 is the standard super duplex wire in 1.0 and 1.2 mm, giving 659 MPa yield, 832 MPa tensile, 159 J at room temperature and 129 J at −40 °C under M12 or M13 shielding.
OK 68.53 is the E2594-16 rutile electrode and OK 68.55 the E2594-15 basic one, both in the ESAB range. Rutile runs more easily and gives a better bead; basic gives tougher weld metal. Where a super duplex procedure sets impact requirements — which it usually does — start from the basic grade. Both are covered on the E2594 stick side of this hub.
Super duplex costs more and has a tighter procedure window. If the parent is 2205 and the service is within its capability, ER2209 is the right consumable and super duplex buys nothing. The decision is made on the parent grade and the service PRE requirement, not on wanting margin — and over-specifying brings a narrower heat input window that is easier to miss on site.
Storage & handling
ESAB lists OK 68.53 and OK 68.55 in the 250 °C re-drying group, two hours. Duplex weld metal with its substantial ferrite fraction is more susceptible to hydrogen-related cracking than a fully austenitic deposit, so the storage discipline matters more here than on 316L.
Heat tint on a super duplex weld is chromium-depleted scale over chromium-depleted metal, in a material chosen specifically for its chloride resistance. Use pickling and passivation chemistry rated for duplex rather than generic stainless product, manual brushing rather than mechanical to avoid forming crevice sites, and abrasives dedicated to stainless.
Frequently asked
Alloy level and the PRE threshold it reaches. Standard duplex consumables such as ER2209 carry around 22 % chromium and 3 % molybdenum, giving a PRE around 35. Super duplex consumables such as ER2594 carry 25 % chromium and 4 % molybdenum, reaching PRE 40 or above. The boundary is a calculated property, not a marketing tier: PRE = %Cr + 3.3 × %Mo + 16 × %N.
ER2594 as wire or TIG rod under AWS A5.9, and E2594 as a covered electrode under A5.4. ESAB supplies Exaton 25.10.4.L and OK Autrod 2509 as wires, and OK 68.53 (rutile) and OK 68.55 (basic) as electrodes. A procedure commonly TIG-roots with the wire and fills with the electrode.
No. A 2209 deposit has a lower PRE than a super duplex parent, so the weld becomes the preferential corrosion site in exactly the service the parent was specified to survive. The joint will pass mechanical and radiographic testing and fail in service. Match the family.
ESAB gives 2 to 15 kJ/cm for super and hyper duplex, with 10 kJ/cm or less preferred on thin sheet, and an interpass temperature not exceeding 150 °C. Both limits are tighter than for standard duplex, which runs 5 to 25 kJ/cm with a 250 °C interpass ceiling. Super duplex precipitates intermetallics more readily because it is more heavily alloyed.
ESAB publishes approximately 50 FN for Exaton 25.10.4.L. The acceptance range for any job comes from the client specification and is generally a tighter window than for 2205, because the consequences of imbalance are greater at this alloy level. Agree the method and limits before welding.
Yes, and it matters more here than on standard duplex. Nitrogen counts three times as heavily as molybdenum in the PRE calculation, so on an alloy selected for its PRE, nitrogen lost from the root pool is a direct loss of the property the material was bought for. ESAB lists N2 among the shielding options for its super duplex TIG grade.
Not for margin alone. Super duplex costs more and has a narrower heat input and interpass window that is easier to miss on site, so over-specifying brings real procedure risk. The decision is made on the parent grade and the service PRE requirement. If the parent is 2205 and the service is within its capability, ER2209 is the right consumable.
POFIS supplies the ESAB OK and Exaton super duplex ranges from Abu Dhabi across the UAE and the wider GCC, as an ESAB Authorized Distributor and Service Centre, approved ADNOC vendor and ISO 9001 certified supplier. Send the parent grade, the PRE requirement, the impact requirement and the ferrite acceptance range and we will confirm the consumable against the procedure. Email weldiv@pofis.ae.
Procurement & supply
The ER2594 / E2594 consumables is supplied from Abu Dhabi by Perfect Oilfield & Industrial Supply LLC as an ESAB Authorized Distributor and Service Centre. The information below covers what procurement and QA/QC departments normally need before raising a purchase order.
Stock items dispatch from Abu Dhabi within 24–48 hours. Indent items are quoted with a confirmed lead time at the time of offer.
POFIS is an approved ADNOC vendor and is listed on the approved vendor lists (AVL) of major operators and EPC contractors across the GCC. We can complete supplier registration and prequalification documentation on request.
Standard credit terms are available to registered corporate accounts. LPO, LC and advance payment are all accepted.
Delivery across the UAE and the wider GCC. Quotations can be issued on EXW, FOB, CIF or DDP terms to suit your project.
Full manufacturer warranty, honoured locally. As an ESAB Authorized Service Centre we carry out warranty work and repairs in Abu Dhabi rather than returning equipment abroad.
In-UAE service, commissioning, operator training and spare parts backing for every machine we supply.
Price on request
Send the form and the POFIS welding division replies with pricing, confirmed lead time, delivery terms and availability. Tell us who you are and what the job is, so the reply can be specific to it rather than a catalogue price list.
