AWS A5.28 ER100S-G Mig Welding Wire

| AWS A 5.28 ER100S-G Mig Welding Wire Description

1）Exceptional High Strength: The "100" in ER100S-G indicates a formidable minimum tensile strength of 100,000 pounds per square inch (psi) in the as-welded condition, which translates to approximately 690 Megapascals (MPa). This makes it significantly stronger than ER70S-6 or ER80S-G wires and positions it for joining base metals that require superior load-bearing capabilities.The AWS A5.28 ER100S-G is a highly specialized solid wire electrode designed for Gas Metal Arc Welding (GMAW) of extremely high-strength, low-alloy steels. It falls under the stringent AWS A5.28 specification, which governs filler metals for this class of materials. The "G" in its classification signifies a "General" category, granting manufacturers the flexibility to tailor its precise chemical composition to achieve specific, often superior, mechanical properties beyond a rigid standard, making it adaptable for the most critical and demanding welding applications.

2）Flexible and Customized Alloying ("G" Classification): The "G" designation is crucial as it allows manufacturers to customize the wire's chemical composition. Unlike fully specified wires, ER100S-G can be formulated with precise amounts of alloying elements such as Nickel (Ni), Chromium (Cr), Molybdenum (Mo), Vanadium (V), and potentially others. This bespoke alloying is done to achieve not just high strength, but also specific performance attributes like exceptional low-temperature impact toughness (e.g., down to -40°C or even -50°C), superior crack resistance, or enhanced creep properties for high-temperature service.

3）Engineered for Superior Weld Metal Properties: ER100S-G wires are meticulously engineered to produce weld metal with a combination of very high strength, excellent ductility, and robust toughness. The precise balance of deoxidizers ensures clean, porosity-free welds even on base metals with some impurities. The resulting weld metal is designed to withstand extreme stresses, dynamic loading, and harsh environmental conditions without compromising integrity.

4）Optimized Arc Characteristics and Wire Feedability: Despite their complex chemistry, ER100S-G wires are formulated for outstanding arc stability and consistent wire feedability. This is critical for achieving high-quality welds, particularly in automated or robotic welding setups where precision and reliability are paramount. Good arc characteristics also contribute to a smooth weld bead appearance and minimal spatter, reducing post-weld cleanup.

5）Shielding Gas Requirements: For optimal performance, ER100S-G wires are typically used with argon-rich shielding gas mixtures, such as 75-95% Argon with the balance being CO2 (e.g., 75% Ar / 25% CO2 or 90% Ar / 10% CO2). These mixtures promote stable spray or pulsed spray transfer modes, which are essential for high deposition rates and superior bead aesthetics. While 100% CO2 may be used in specific cases for deeper penetration, it can lead to increased spatter and potentially affect mechanical properties if not precisely controlled.

6）Applications in Ultra-Demanding Industries: ER100S-G is reserved for the most critical and demanding applications where maximum strength and reliability are non-negotiable. This includes the fabrication of heavy earth-moving and construction machinery, highly stressed components in bridges, offshore platforms, military applications (such as armored vehicles and HY-80 steel welding), pressure vessels, and specialized piping in power generation and petrochemical industries. Its use ensures the longevity and safety of structures under extreme operational conditions, emphasizing its role in critical infrastructure welding.

| AWS A5.28 ER100S-G Mig Welding Wire Down Load

AWS A5.28 -ER100S-G Mig Welding Wire.pdf

| AWS A5.28 ER100S-G Mig Welding Wire Data Sheet

Standard： AWS A5.28 ER100S-G

Chemical Composition %

C

Mn

Si

P

S

Ti

Ni

Cu

Cr

B

Grade ER100S-G

≤0.08

1.25 ~ 1.80

0.20 ~ 0.55

≤0.01

≤0.01

≤0.10

1.40 ~ 2.10

≤0.25

≤0.30

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Type

Spool  ( MIG )

Tube  ( TIG )

Specification  ( MM )

0.8、0.9、1.0、1.2、1.6、2.0

1.6、2.0、2.4、3.2、4.0、5.0

Package

S100 / 1kg                     S200 / 5kg S270,S300 / 15kg-20kg

5kg / box    10kg / box    length :1000MM

Mechanical Properties

Tensile Strength Mpa

Yield Strength Mpa

Elongation A  (%)

Impact Value KV2 (J)   -30℃

≥ 690

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Diameter（MM）

0.8

1.0

1.2

1.6

MIG Welding

Welding Current ( A )

50 – 100

50 – 220

80 – 350

170 – 550

CO2Gas-flow ( L/min )

15

15 – 20

15 – 25

20 – 25

AWS A5.28 ER100S-G Mig Welding Wire Parameters
Diameter		Process		Volt		Amps		Shielding GAS		Travel Speed       (ipm)
in	mm
0.023	0.6	GMAW		14-19		30-85		Short Circuiting 98%Argon + 2%Oxygen		10-15
0.03	0.8	GMAW		15-20		40-130		Spray Transfer 98%Argon + 2%Oxygen		12-24
0.035	0.9	GMAW		23-26		160-300		Spray Transfer 98%Argon + 2%Oxygen		11-22
0.039	1.0	GMAW		28-31		200-320		Spray Transfer 98%Argon + 2%Oxygen		15-20
1/25.4”
0.045	1.2	GMAW		23-29		170-375		Spray Transfer 98%Argon + 2%Oxygen		12-21
3/64”
1/16”	1.6	GMAW		25-31		275-475		Spray Transfer 98%Argon + 2%Oxygen		9-19
Diameter		Process		Volt		Amps		GAS		Travel Speed (ipm)
in	mm
0.035	0.9	GTAW		12-15		60-100		100%Argon		N / A
0.045	1.2	GTAW		13-16		70-120		100%Argon		N / A
1/16”	1.6	GTAW		adjust to current		100-160		100%Argon		N / A
3/32”	2.4	GTAW		adjust to current		120-250		100%Argon		N / A
1/8”	3.2	GTAW		adjust to current		150-300		100%Argon		N / A
Weight	0.5kg	1kg	2kg		5kg	15kg		20kg
	1 lb	2 lb	4 lb		11 lb	33 lb		44 lb

| AWS A5.28 ER100S-G Mig Welding Wire Workshop Show

| AWS A5.28 ER100S-G Mig Welding Wire Production Video

| AWS A5.28 ER100S-G Mig Welding Wire Application

| AWS A5.28 ER100S-G Mig Welding Wire Certificate

| AWS A5.28 ER100S-G Mig Welding Wire Comment & FAQ

Question 1: What does the "100" in AWS A5.28 ER100S-G represent?

The "100" in ER100S-G denotes the minimum tensile strength of the deposited weld metal in thousands of pounds per square inch (ksi).
Specifically, it means the weld will have a minimum tensile strength of 100,000 psi (approximately 690 MPa).
This places it in the category of very **high-strength welding wires**, designed for demanding structural applications.

Question 2: How does the "G" classification impact the composition of ER100S-G?

The "G" signifies a "General" classification, meaning the exact chemical composition of the wire is not rigidly prescribed by AWS.
This flexibility allows manufacturers to tailor the wire's alloying elements, such as **Nickel (Ni), Chromium (Cr), and Molybdenum (Mo)**, to achieve specific mechanical properties or performance characteristics beyond just strength.
It enables bespoke solutions for unique **welding challenges**.

Question 3: What types of steels is ER100S-G specifically designed to weld?

ER100S-G is engineered for welding high-strength, low-alloy steels, particularly those with a minimum yield strength of 100 ksi or similar.
This includes various quenched and tempered steels, military-grade steels like HY-80, and other advanced structural steels where the weld joint must match the base metal's exceptional strength and toughness.
It's crucial for **critical steel fabrication**.

Question 4: What are the key mechanical properties targeted by ER100S-G formulations?

Beyond its high tensile strength, ER100S-G wires are formulated for exceptional **impact toughness**, often at very low temperatures (down to -40°C or -50°C), excellent ductility, and superior crack resistance.
These properties ensure the weld can withstand extreme stresses, dynamic loading, and harsh environments, vital for **structural integrity** in critical applications.

Question 5: What shielding gases are most suitable for welding with ER100S-G?

For optimal performance, ER100S-G wires are typically used with argon-rich shielding gas mixtures, such as 75-95% Argon with the balance being CO2 (e.g., 90% Ar / 10% CO2).
These mixtures facilitate stable spray or pulsed spray transfer, which is essential for achieving high deposition rates, minimal spatter, and a superior **weld bead appearance**.
Pure CO2 is generally not recommended as it can negatively affect mechanical properties.

Question 6: Is preheating often required when welding with ER100S-G?

Yes, preheating is almost always required when welding with ER100S-G, especially on thicker sections or highly restrained joints.
Due to the high strength and alloy content of both the wire and the base metals, preheating helps slow down the cooling rate, significantly reducing the risk of **hydrogen-induced cracking** and ensuring sound welds.
Specific preheat temperatures will depend on the base material and joint configuration.

Question 7: How does ER100S-G perform in automated or robotic welding environments?

ER100S-G wires are designed for excellent arc stability and consistent wire feedability, making them highly suitable for automated and robotic welding systems.
Their reliable performance allows for precise control, high deposition rates, and extended arc-on time, contributing to significant increases in **welding productivity** and consistency in high-volume production.

Question 8: What are some typical applications where ER100S-G wire is indispensable?

ER100S-G is indispensable in the most demanding industries.
Applications include heavy earth-moving equipment, military vehicles (like armored personnel carriers, often involving HY-80 or HY-100 steels), offshore drilling platforms, critical components in bridges and power generation facilities, and specialized high-pressure vessels where maximum strength and toughness are non-negotiable.
It's vital for **mission-critical welding**.

Question 9: Can ER100S-G be used for all welding positions?

While optimal results are typically achieved in flat and horizontal positions with spray transfer, ER100S-G can be used for all welding positions (flat, horizontal, vertical-up, overhead) with appropriate parameters and techniques.
For out-of-position welding, pulsed spray or short-circuit transfer with specific wire diameters is often employed to manage the weld puddle effectively, offering **welding versatility**.

Question 10: How does ER100S-G manage potential hydrogen cracking in high-strength steels?

Managing hydrogen is paramount for high-strength steel welding with ER100S-G.
This involves using extremely dry wire, controlling interpass temperatures, employing adequate preheat, and sometimes conducting post-weld heat treatment (PWHT).
The wire's specific chemistry is also designed to minimize hydrogen pick-up, contributing to enhanced **crack resistance**.
Strict adherence to **welding procedure specifications (WPS)** is essential.

Question 11: What is the significance of the copper coating on ER100S-G wires?

The copper coating on ER100S-G wire serves to improve electrical conductivity, enhance smooth wire feeding through the gun liner and contact tip, and provide some corrosion resistance to the wire itself before use.
It ensures reliable arc starting and consistent current transfer, critical for maintaining the high-quality standards expected of **premium welding wires**.

Question 12: What type of weld bead appearance can be expected with ER100S-G?

When used correctly, ER100S-G produces a very smooth, consistent, and clean weld bead.
Its optimized composition contributes to excellent weld puddle fluidity and good wetting, resulting in minimal spatter and a highly desirable aesthetic finish.
This reduces the need for extensive post-weld cleanup, enhancing **fabrication efficiency**.

Question 13: Is post-weld heat treatment (PWHT) commonly required for ER100S-G welds?

Yes, **post-weld heat treatment (PWHT)** is frequently required for ER100S-G welds, especially on critical components or thick sections.
PWHT helps to temper the weld metal and heat-affected zone (HAZ), relieve residual stresses, and optimize the final mechanical properties, particularly toughness and ductility.
It's a crucial step in ensuring the long-term performance of **high-strength weldments**.

Question 14: How does ER100S-G contribute to the longevity of components in extreme environments?

By providing superior strength, exceptional low-temperature toughness, and in some cases, improved creep or corrosion resistance, ER100S-G welds significantly enhance the longevity and reliability of components operating in extreme environments.
It ensures structures can withstand harsh conditions, dynamic loads, and fatigue over extended service lives, crucial for **engineering resilience**.

Question 15: Are there specific industry approvals or certifications for ER100S-G?

Yes, given its critical applications, ER100S-G typically carries numerous industry approvals from major classification societies.
These can include Lloyd's Register, DNV, ABS, Bureau Veritas, and others, especially for shipbuilding, offshore structures, and military applications, confirming its suitability for adherence to strict **welding codes and standards**.

Question 16: What wire diameters are typically available for ER100S-G?

ER100S-G is available in common wire diameters suitable for high-strength MIG welding applications, such as 0.035 inch (0.9 mm), 0.045 inch (1.2 mm), and 1/16 inch (1.6 mm).
The selection of **welding wire diameter** depends on the base metal thickness, desired deposition rate, and the capabilities of the welding equipment and power source.

Question 17: How does ER100S-G compare to flux-cored wires for high-strength steels?

While both can weld high-strength steels, ER100S-G is a solid wire, requiring external shielding gas, and generally produces less fume and spatter, offering a cleaner welding environment.
Flux-cored wires (like E100T-X) offer higher deposition rates in some positions but might produce more slag and fumes.
The choice depends on the specific **welding process** preference, application, and productivity goals.

Question 18: What are potential challenges or considerations for welders using ER100S-G?

Welders using ER100S-G must maintain precise parameter control, manage interpass temperatures diligently, and often adhere to strict preheat/PWHT procedures.
Understanding the specific metallurgy of the high-strength base metal is also crucial.
The higher cost of the wire and the importance of defect-free welds necessitate a highly skilled operator and rigorous **welding quality control**.

Question 19: Can ER100S-G be used to weld dissimilar metals?

While its primary use is for welding similar high-strength low-alloy steels, ER100S-G *might* be used for certain dissimilar metal combinations if the mechanical properties of the weld metal are compatible with both base materials and specific engineering requirements are met.
However, such applications require careful metallurgical analysis and specific **welding procedure qualification**.

Question 20: Where can I find detailed technical specifications for a specific ER100S-G product?

Given the "G" classification, it's paramount to obtain the precise technical data sheet directly from the welding wire manufacturer.
This document will detail the exact chemical analysis, comprehensive mechanical properties (including elongation and specific Charpy V-notch values), recommended shielding gases, and specific welding parameters for their particular **ER100S-G formulation**.
It's your go-to source for precise information.

Question 21: What makes AWS A5.28 ER120S-G a unique welding wire?

The "120" in ER120S-G signifies an exceptionally high minimum tensile strength of 120,000 psi (approximately 827 MPa) in the deposited weld metal.
This places it among the strongest solid MIG welding wires available, designed for welding ultra-high-strength low-alloy steels.
The "G" classification allows manufacturers to precisely tailor the wire's complex alloy chemistry (often including high levels of **Nickel, Chromium, and Molybdenum**) to achieve this strength alongside superior toughness and crack resistance, making it suitable for the most critical and demanding applications.

Question 22: What are the typical applications for ER120S-G welding wire?

ER120S-G is reserved for the most stringent applications where absolute maximum strength and integrity are paramount.
This includes the fabrication of components for military defense (e.g., armored vehicles, submarines using HY-100 or HY-130 steels), heavy lifting equipment, specialized offshore structures, and critical parts in the aerospace industry or high-performance pressure vessels.
It's vital for **extreme engineering projects** where failure is not an option.

Question 23: What specific mechanical properties are emphasized in ER120S-G weld metal?

Beyond its remarkable tensile strength, ER120S-G weld metal is characterized by outstanding **low-temperature impact toughness**, often specified at temperatures as low as -40°C, -50°C, or even -60°C.
It also offers excellent ductility and superior resistance to cracking, even under highly restrained conditions.
These properties ensure the weld can withstand severe dynamic loads and operate reliably in frigid environments, making it ideal for **high-performance structures**.

Question 24: What are the critical considerations for welding with ER120S-G?

Welding with ER120S-G requires meticulous attention to detail and a highly controlled process.
This includes strict adherence to preheat and interpass temperature requirements, precise control over heat input, and diligent hydrogen management (e.g., extremely dry wire, optimal shielding gas, potential post-weld heat treatment).
The base metals used with this wire are inherently susceptible to cracking, so comprehensive **welding procedure specifications (WPS)** and skilled operators are essential for success and to ensure **weld integrity**.

Question 25: What shielding gases and welding parameters are typically used with ER120S-G?

ER120S-G is almost exclusively used with argon-rich shielding gas mixtures, such as 90% Argon / 10% CO2 or even 98% Argon / 2% Oxygen, to ensure stable spray or pulsed spray transfer.
These gases provide the best arc stability, minimal spatter, and optimal control over the weld pool, crucial for high-quality, high-strength welds.
Parameters must be carefully calibrated to manage heat input and achieve the desired mechanical properties, often requiring advanced **MIG welding equipment** with synergic capabilities.

Question 26: How does ER120S-G contribute to the longevity and reliability of welded components?

ER120S-G's combination of ultra-high strength, exceptional toughness, and crack resistance directly contributes to the superior longevity and reliability of welded components.
By providing welds that can withstand extreme mechanical stresses, fatigue, and challenging environmental conditions (like very low temperatures or high pressures), it ensures that critical structures and machinery maintain their integrity and operational safety over their intended service life, reducing maintenance and replacement costs in **demanding service environments**.