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.
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, A514, A517 | 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 |
Use ER80S-D2 when:
Use ER70S-6 when:
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.
Where to Buy
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