ER80S-D2 High-Strength MIG Wire for Structural Steel
ER80S-D2 Amperage by Diameter
| Diameter | Amperage Range |
|---|---|
| 0.030" (0.8 mm) | 50 - 180A |
| 0.035" (0.9 mm) | 75 - 250A |
| 0.045" (1.2 mm) | 125 - 350A |
ER80S-D2 is a solid MIG wire classified under AWS A5.28 for welding high-strength low-alloy (HSLA) steels. It deposits weld metal with approximately 80,000 psi tensile strength, making it suitable for base metals with yield strengths up to 80 ksi including ASTM A514, A517, A572 Gr.50-65, and similar HSLA grades. The wire contains approximately 0.5% molybdenum and higher manganese than ER70S-6, which provide the increased strength and improved low-temperature toughness. ER80S-D2 is also commonly used for welding chrome-moly (Cr-Mo) piping such as 1/2Cr-1/2Mo materials. For MIG welding, use with 75/25 Ar/CO2 or 90/10 Ar/CO2 shielding gas. For TIG, use 100% argon. Preheat and interpass temperature requirements follow the base metal specification.
What This Means in Practice
ER80S-D2 is a step up from ER70S-6 when you need stronger weld metal. The 80 in the name means 80,000 psi tensile strength (vs 70,000 for ER70S-6). It contains approximately 0.5% molybdenum which improves strength and toughness. Use it when the base metal is stronger than standard A36 and the weld needs to match.
ER80S-D2 Suitability Scores
How well this electrode matches common applications. Not a quality rating. all AWS-certified electrodes meet their specification.
When to Use ER80S-D2
Use ER80S-D2 when the base metal has a yield strength above 50 ksi and standard ER70S-6 would produce an undermatched weld.
Required for HSLA steels in structural, heavy equipment, and pressure vessel applications.
Also used for chrome-moly piping root and fill passes where MIG/TIG is preferred over stick.
ER80S-D2 Limitations
More expensive than ER70S-6.
Requires more precise heat input control.
Not suitable for standard mild steel applications where ER70S-6 is sufficient.
May require preheat on thicker sections.
The higher strength weld is more susceptible to hydrogen cracking if moisture is present.
ER80S-D2 Storage Requirements
Store in dry conditions. Keep wire clean and free of oil or moisture. Clean, dry wire is critical for preventing hydrogen cracking in high-strength weld deposits.
ER80S-D2 Technical Specifications
| Property | Value |
|---|---|
| AWS Classification | ER80S-D2 |
| Process | mig-wire () |
| Polarity | DCEP |
| Positions | flat, horizontal, vertical up, overhead |
| Penetration | medium-deep |
| Coating Type | bare wire |
| Tensile Strength | 80,000 psi |
| Yield Strength | 68,000 psi |
| Elongation | 19% |
| Base Metals | HSLA steels (A572, A514, A517), Chrome-moly steel, High-strength structural steel |
| Shielding Gas | 75/25 Ar/CO2 or 90/10 Ar/CO2 |
| AWS Specification | A5.28 |
Frequently Asked Questions
When should I use ER80S-D2 instead of ER70S-6?
Use ER80S-D2 when the base metal has a yield strength above 50 ksi (such as A572 Gr.65, A514, or A517) and ER70S-6 would produce an undermatched weld. The 80,000 psi tensile strength of ER80S-D2 matches high-strength low-alloy (HSLA) steels. For standard A36 or mild steel, ER70S-6 is sufficient and more cost-effective.
What shielding gas should I use with ER80S-D2?
Use 75/25 Ar/CO2 for general MIG welding. For applications requiring maximum toughness, use 90/10 Ar/CO2 or 95/5 Ar/CO2 which reduces oxygen in the weld deposit. 100% CO2 provides deeper penetration but increases spatter and reduces impact toughness. For TIG welding, use 100% argon.
Does ER80S-D2 require preheat?
Preheat requirements depend on the base metal, not the wire. However, because ER80S-D2 is used on higher-strength steels, preheat is more commonly required. Follow the base metal specification or welding code for preheat temperatures. A common starting point is 200-300F for plates over 1 inch thick in HSLA steels.
External Resources
Manufacturer data sheets and standards for ER80S-D2.
Data sourced from AWS A5.28/A5.28M. Amperage ranges are approximate starting points. adjust based on position, fit-up, and material thickness. Always follow manufacturer recommendations and applicable codes.