AWS A5.28 ER80S-G Mig Welding Wire

| AWS A 5.28 ER80S-G Mig Welding Wire Description

1）Strength and Alloy Content: The "80" in ER80S-G signifies that the deposited weld metal has a minimum tensile strength of 80,000 pounds per square inch (psi), or approximately 550 MPa. This higher strength distinguishes it from common mild steel wires (like ER70S-6). The "G" classification allows for various alloying elements (such as Molybdenum (Mo), Chromium (Cr), Nickel (Ni), Vanadium (V), etc.) to be present, tailored by the manufacturer to achieve specific mechanical properties or performance characteristics in the weld.The AWS A5.28 ER80S-G classification designates a solid wire electrode specifically designed for Gas Metal Arc Welding (GMAW), commonly known as MIG welding, of low-alloy steels. This designation falls under the AWS A5.28 specification, which covers filler metals for welding low-alloy steels. The "G" classification implies a general-purpose filler metal where the exact chemical composition and mechanical properties are not fully prescribed by the AWS standard but are instead agreed upon between the manufacturer and the user, offering flexibility for specific application requirements.

2）"G" Classification Flexibility: The "G" in ER80S-G is a unique aspect, meaning "General." Unlike other AWS classifications that define precise chemical composition ranges, the "G" allows for variation. Manufacturers use this flexibility to produce wires that meet the 80 ksi tensile strength requirement while being optimized for particular applications or base metals, such as specific creep-resistant steels, weathering steels, or those requiring enhanced toughness at low temperatures.

3）Key Characteristics and Performance: ER80S-G wires are typically characterized by good arc stability, consistent wire feeding, and reliable weld metal transfer. Depending on the specific manufacturer's formulation, they may offer good deoxidation properties, resistance to atmospheric corrosion (especially those with Cu, Cr, Ni additions for weathering steels), or improved creep resistance for elevated temperature service. The weld beads are generally smooth, promoting good appearance and reducing post-weld cleanup.

4）Shielding Gas Recommendations: For ER80S-G wires, common shielding gases include Argon/CO2 mixtures (e.g., 75% Ar / 25% CO2, or 80% Ar / 20% CO2) or 100% CO2. Argon-rich mixtures often provide a more stable arc, less spatter, and better bead shape, particularly for spray or pulsed spray transfer. 100% CO2 can offer deeper penetration and lower cost for specific applications, though it might result in more spatter. The choice of shielding gas is crucial and often specified by the manufacturer for optimal results.

5）Applications in Demanding Industries: Due to its elevated strength and tailored alloying, ER80S-G is widely used in demanding industries. Key applications include the welding of high-strength structural steels in construction (e.g., bridges, high-rise buildings), heavy machinery, earth-moving equipment, pressure vessels, and piping systems that operate at elevated temperatures (e.g., in power generation or petrochemical facilities). It is also used for welding weathering steels like Corten.

6）Suitability for Critical and High-Strength Steels: This wire is a go-to choice for joining low-alloy, high-strength steels where the final weld must possess mechanical properties comparable to or exceeding the base material. Its versatility, stemming from the "G" classification, allows it to be formulated for specific applications where properties like good impact toughness at low temperatures or resistance to hydrogen and sulfur attacks are essential for weld integrity in challenging service conditions.

| AWS A5.28 ER80S-G Mig Welding Wire Down Load

AWS A5.28 -ER80S-G Mig Welding Wire.pdf

| AWS A5.28 ER80S-G Mig Welding Wire Data Sheet

| AWS A5.28 ER80S-G Mig Welding Wire Workshop Show

| AWS A5.28 ER80S-G Mig Welding Wire Production Video

| AWS A5.28 ER80S-G Mig Welding Wire Application

| AWS A5.28 ER80S-G Mig Welding Wire Certificate

| AWS A5.28 ER80S-G Mig Welding Wire Comment & FAQ

Question 1: What does the "80" in AWS A5.28 ER80S-G signify?

The "80" in ER80S-G indicates that the deposited weld metal will have a minimum tensile strength of 80,000 pounds per square inch (psi), which is approximately 550 Megapascals (MPa).
This places it in a higher strength category compared to common mild steel wires, making it suitable for demanding **structural applications** and high-strength low-alloy steels.

Question 2: What does the "G" classification mean for ER80S-G?

The "G" stands for "General Classification."
It means the exact chemical composition of the wire is not rigidly defined by the AWS standard itself.
Instead, the specific alloying elements and their percentages are left to the manufacturer's discretion, as long as the wire meets the specified mechanical properties (like the 80 ksi tensile strength).
This allows for tailored **welding wire formulations** to suit specific applications or base metals, offering flexibility in design.

Question 3: What types of alloying elements are typically found in ER80S-G wires?

Given its higher strength and "G" classification, ER80S-G wires often contain alloying elements such as **Molybdenum (Mo)**, **Chromium (Cr)**, **Nickel (Ni)**, and sometimes Vanadium (V) or Copper (Cu).
These elements are added to achieve specific properties like improved tensile strength, enhanced toughness, creep resistance at elevated temperatures, or better atmospheric corrosion resistance for **weathering steels**.

Question 4: What kind of base metals is ER80S-G primarily used to weld?

ER80S-G is specifically designed for welding low-alloy, high-strength steels where the weld metal needs to match or exceed the mechanical properties of the base material.
This includes various quenched and tempered steels, certain normalized steels, and specialized steels used in demanding industries.
It's crucial for **high-strength steel fabrication**.

Question 5: What are the main advantages of using ER80S-G welding wire?

The primary advantages include its ability to produce high-strength welds that match advanced base materials, its adaptability through various manufacturer-specific formulations for specialized properties (like toughness or creep resistance), and its suitability for critical applications where standard mild steel wires fall short.
It's a versatile choice for complex **engineering projects**.

Question 6: What are the recommended shielding gases for ER80S-G?

Common shielding gases for ER80S-G include Argon/CO2 mixtures (e.g., 75% Ar / 25% CO2, or 80% Ar / 20% CO2) or 100% CO2.
Argon-rich mixes often provide a smoother arc, less spatter, and better bead appearance, especially for spray or pulsed spray transfer.
100% CO2 offers deeper penetration and can be more cost-effective for specific **MIG welding applications**.

Question 7: How does ER80S-G differ from an ER70S-6 wire?

The main difference lies in strength and alloying.
ER80S-G offers a higher minimum tensile strength (80 ksi vs. 70 ksi for ER70S-6) and contains specific alloying elements beyond just manganese and silicon.
ER70S-6 is for mild steels, while ER80S-G is for low-alloy high-strength steels, making it a more specialized **welding consumable** for demanding applications.

Question 8: Is ER80S-G suitable for applications requiring elevated temperature service?

Yes, many ER80S-G formulations are specifically designed for elevated temperature service.
Wires alloyed with chromium (Cr) and molybdenum (Mo) (e.g., ER80S-B2, B3, B6, B8 sub-types if it were not "G") fall under the A5.28 specification and are known for their improved **creep resistance** at high temperatures.
The "G" classification allows for such specialized formulations.

Question 9: Can ER80S-G be used for low-temperature impact toughness applications?

Yes, certain ER80S-G formulations are designed to provide excellent low-temperature impact toughness.
Manufacturers can adjust the alloying elements (e.g., adding Nickel) to ensure the weld metal maintains ductility and resists brittle fracture even at very low temperatures.
Always check the manufacturer's data sheet for specific **Charpy V-notch** impact values at specified temperatures.

Question 10: What are common industries that utilize ER80S-G welding wire?

Industries that heavily rely on ER80S-G include heavy equipment manufacturing (e.g., excavators, cranes), structural steel construction (especially for bridges and high-rise buildings), pressure vessel and boiler fabrication, power generation (for piping and components), and petrochemical industries.
It's vital for any sector building with **high-strength materials**.

Question 11: Is preheating often required when welding with ER80S-G?

Yes, due to the higher strength and alloy content of the base metals often welded with ER80S-G, preheating is frequently required.
Preheating helps to slow down the cooling rate of the weld and heat-affected zone (HAZ), reducing the risk of hydrogen-induced cracking and ensuring optimal **weld integrity** in critical applications.
Refer to base metal specifications for precise preheat temperatures.

Question 12: How does the "G" classification impact quality control and certification?

While the "G" offers flexibility in composition, manufacturers producing ER80S-G wire must still adhere to rigorous quality control to ensure the deposited weld metal meets the minimum 80 ksi tensile strength and any other agreed-upon mechanical properties.
They will provide certificates of conformance detailing the specific chemical analysis and mechanical test results for their particular **ER80S-G product**, ensuring traceability and quality.

Question 13: Can ER80S-G be used for root passes on pipes and pressure vessels?

Yes, depending on the specific formulation and welding procedure, certain ER80S-G wires can be used for root passes.
Their stable arc and controlled puddle characteristics, coupled with appropriate welding techniques, can achieve good penetration and fusion in critical root pass applications.
This is vital for industries focused on **pressure containment**.

Question 14: Is ER80S-G suitable for automated and robotic welding systems?

Yes, many manufacturers formulate their ER80S-G wires with excellent wire feeding characteristics, arc stability, and consistent performance across a range of parameters.
These attributes make them highly suitable for automated and robotic welding applications, contributing to increased deposition rates and improved efficiency in **high-volume fabrication**.

Question 15: What kind of weld bead appearance can be expected with ER80S-G?

The weld bead appearance with ER80S-G is typically smooth, uniform, and aesthetically pleasing, especially when used with optimized Argon/CO2 mixes.
Manufacturers aim for good wetting and minimal spatter, which reduces the need for post-weld cleanup and grinding.
This contributes to a high-quality finish on **fabricated components**.

Question 16: Are there specific considerations for managing hydrogen when using ER80S-G?

Yes, managing hydrogen is crucial, especially when welding high-strength low-alloy steels with ER80S-G.
This involves using dry, clean wire, ensuring appropriate shielding gas quality, and sometimes employing preheat and post-weld heat treatment (PWHT) to prevent hydrogen-induced cracking.
Proper **welding procedure specifications (WPS)** are critical for hydrogen control.

Question 17: How does ER80S-G contribute to the service life of welded components?

By providing higher strength, and in some cases, enhanced toughness or creep resistance, ER80S-G welds contribute significantly to the extended service life and reliability of welded components.
This is especially true for structures subjected to high stresses, extreme temperatures, or corrosive environments.
It's an investment in long-term **structural integrity**.

Question 18: Can ER80S-G be used for all welding positions?

Yes, with appropriate welding parameters and techniques, ER80S-G wires are versatile enough for all-position welding (flat, horizontal, vertical-up, overhead).
The choice of wire diameter and transfer mode (e.g., short circuit for out-of-position, spray for flat/horizontal) plays a key role in achieving successful welds in different orientations.
It offers broad **welding maneuverability**.

Question 19: What should I look for on a manufacturer's data sheet for an ER80S-G wire?

When reviewing an ER80S-G data sheet, look for the detailed chemical analysis (specific alloying elements), precise mechanical properties (tensile strength, yield strength, elongation, and especially Charpy V-notch impact values at specified temperatures).
Also, note the recommended shielding gases, welding parameters, and any specific applications or approvals.
This ensures the **welding wire selection** matches your needs perfectly.

Question 20: How does ER80S-G relate to other AWS A5.28 classifications like ER80S-Ni1 or ER80S-B2?

ER80S-Ni1 and ER80S-B2 are specific subclasses under AWS A5.28, where the exact chemical composition (e.g., 1% Nickel for Ni1, specific Cr-Mo for B2) is precisely defined.
ER80S-G is a more general category that allows a wider range of alloying elements to meet the 80 ksi strength requirement.
A manufacturer might create an ER80S-G wire that performs similarly to a specific subclass but with a slightly different, proprietary chemistry, offering a tailored solution for unique **low-alloy steel welding** challenges.