High-Strength vs Standard MIG Wire
ER80S-D2 (80 ksi) for HSLA steel vs ER70S-6 (70 ksi) for mild steel. Match wire strength to base metal strength.
Which One Should You Use?
Pick ER80S-D2 if:
Runs on DCEP, 50-350A range. ER80S-D2 full amperage chart
Key Differences
| Attribute | ER80S-D2 | ER70S-6 |
|---|---|---|
| Tensile Strength | 80,000 psi | 70,000 psi |
| Yield Strength | 68,000 psi | 58,000 psi |
| Molybdenum | ~0.5% Mo | None |
| Base Metal Match | HSLA: A572 Gr.50-65, A588, and similar 50-65 ksi yield steels | Mild steel: A36, A500 |
| Cost | 30-50% more | Standard pricing |
| Preheat Requirement | May require preheat on thick sections | Rarely needs preheat |
| AWS Standard | A5.28 (low-alloy wire) | A5.18 (carbon steel wire) |
| Availability | Welding distributors | Everywhere - hardware to Amazon |
Settings at a Glance
Machine settings and operating characteristics side by side. For full amperage charts, see the individual electrode pages.
| Setting | ER80S-D2 | ER70S-6 |
|---|---|---|
| Polarity | DCEP | DCEP |
| Positions | flat, horizontal, vertical-up, overhead | flat, horizontal, vertical-up, overhead |
| Penetration | medium-deep | medium |
| Coating | bare wire | copper-coated solid wire |
| Amps at 0.030" | 50-180A | 40-145A |
| Amps at 0.035" | 75-250A | 50-220A |
| Amps at 0.045" | 125-350A | 75-350A |
How ER80S-D2 and ER70S-6 Work Together
ER70S-6 is the universal MIG wire for A36 and common mild steel. ER80S-D2 is needed only when the base metal is HSLA with yield strength above 50 ksi. Using ER80S-D2 on mild steel adds cost with no benefit. Using ER70S-6 on high-strength steel produces an undermatched weld that may fail. Check the base metal specification and match the wire.
Common Mistake With High-Strength
Using ER80S-D2 on mild steel thinking stronger wire makes stronger welds. The weld strength needs to match the base metal. An 80 ksi weld on a 36 ksi base metal concentrates stress at the heat-affected zone and can actually promote cracking in some joint configurations.
Practical Differences
| Factor | ER80S-D2 | ER70S-6 |
|---|---|---|
| Common Brands | SuperArc LA-75, HB-25 ER80S-D2 | SuperArc L-56, HB-28 |
Where to Buy
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ER80S-D2 vs ER70S-6: Common Questions
Which is better, ER80S-D2 or ER70S-6?
Wrong question. They solve different problems. Key differences: Tensile Strength: ER80S-D2 has 80,000 psi, while ER70S-6 has 70,000 psi. Yield Strength: ER80S-D2 has 68,000 psi, while ER70S-6 has 58,000 psi. Molybdenum: ER80S-D2 has ~0.5% mo, while ER70S-6 has none. The comparison table on this page breaks down each trade-off.
Can I substitute ER80S-D2 for ER70S-6?
Only if the specs allow it. Penetration differs: ER80S-D2 is medium-deep, ER70S-6 is medium. Coating chemistry is different (bare wire vs copper-coated solid wire), so the arc and slag behave differently.
Can I use both ER80S-D2 and ER70S-6 on the same joint?
ER70S-6 is the universal MIG wire for A36 and common mild steel. ER80S-D2 is needed only when the base metal is HSLA with yield strength above 50 ksi. Using ER80S-D2 on mild steel adds cost with no benefit. Using ER70S-6 on high-strength steel produces an undermatched weld that may fail. Check the base metal specification and match the wire.
Reference data only. Verify all settings against manufacturer documentation and the applicable welding code before use. Amperage ranges are starting points that vary by position, fit-up, and material. Welding involves serious injury risks including burns, electric shock, fume exposure, and fire. This site does not replace proper training, certification, or employer safety procedures. See full terms of use.
Data sourced from AWS A5.28/A5.28M, AWS A5.18/A5.18M.