AWS A5.28 ER90S-G Mig Welding Wire

| AWS A 5.28 ER90S-G Mig Welding Wire Description

1）High Strength Designation: The "90" in ER90S-G signifies that the deposited weld metal will achieve a minimum tensile strength of 90,000 pounds per square inch (psi), equivalent to approximately 620 Megapascals (MPa). This positions it as a significantly stronger wire than standard mild steel options, making it essential for joining high-strength steels where the weld needs to match the strength of the base material.The AWS A5.28 ER90S-G classification denotes a solid wire electrode specifically designed for Gas Metal Arc Welding (GMAW) of low-alloy, high-strength steels. This wire is part of the AWS A5.28 specification, which covers filler metals for this category of steel. The "G" in the classification indicates a "general" filler metal, meaning its precise chemical composition and mechanical properties are not fully dictated by the AWS standard itself but are instead agreed upon between the manufacturer and the end-user. This flexibility allows manufacturers to tailor the wire for highly specific applications requiring enhanced properties.

2）Flexible "G" Composition: The "G" classification is a key feature, indicating that the manufacturer has flexibility in the wire's exact chemical composition. Unlike other specific classifications (e.g., ER90S-D2, ER90S-B3), ER90S-G allows for variations in alloying elements like Nickel (Ni), Chromium (Cr), Molybdenum (Mo), Vanadium (V), or Tungsten (W). This allows manufacturers to optimize the wire for specific needs such as superior toughness, improved creep resistance, or better resistance to atmospheric corrosion.

3）Engineered for Demanding Properties: ER90S-G wires are carefully engineered to deliver a combination of high strength and often enhanced properties like excellent impact toughness, even at very low temperatures (e.g., -30°C or -40°C), or superior creep rupture strength for elevated temperature service. This makes them critical for components operating under harsh conditions or dynamic loads.

4）Optimized Arc Characteristics: Manufacturers typically design ER90S-G wires to provide stable arc performance, good wire feedability, and controlled weld puddle characteristics. This results in consistent, high-quality welds with good bead shape and minimal spatter, which is crucial for achieving high productivity and reducing post-weld cleanup in demanding fabrication environments.

5）Shielding Gas Compatibility: For optimal results, ER90S-G wires are commonly used with Argon/CO2 gas mixtures (e.g., 75% Ar / 25% CO2, or 80% Ar / 20% CO2). These gas mixtures promote a stable spray or pulsed spray transfer mode, leading to high deposition rates and excellent bead appearance. While 100% CO2 can be used for certain applications to achieve deeper penetration, the mixed gases generally offer superior arc stability and less spatter.

6）Applications in Critical Industries: This wire is vital for industries involved in heavy fabrication and critical infrastructure. Common applications include the welding of high-strength structural components for bridges and large buildings, heavy machinery and earth-moving equipment, high-pressure pipelines, pressure vessels, and specialized components in the power generation and petrochemical industries. Its ability to join advanced materials reliably underscores its importance in critical welding projects.

| AWS A5.28 ER90S-G Mig Welding Wire Down Load

AWS A5.28 -ER90S-G Mig Welding Wire.pdf

| AWS A5.28 ER90S-G Mig Welding Wire Data Sheet

| AWS A5.28 ER90S-G Mig Welding Wire Workshop Show

| AWS A5.28 ER90S-G Mig Welding Wire Production Video

| AWS A5.28 ER90S-G Mig Welding Wire Application

| AWS A5.28 ER90S-G Mig Welding Wire Certificate

| AWS A5.28 ER90S-G Mig Welding Wire Comment & FAQ

Question 1: What is the primary characteristic indicated by the "90" in ER90S-G?

The "90" in ER90S-G signifies the minimum tensile strength of the deposited weld metal, which is 90,000 pounds per square inch (psi), or approximately 620 Megapascals (MPa).
This places it in a higher strength class than common mild steel wires, making it essential for **high-strength applications** where robust mechanical properties are critical.

Question 2: What does the "G" classification in ER90S-G imply for its composition?

The "G" stands for "General Classification," meaning the exact chemical composition isn't strictly defined by AWS.
Instead, manufacturers have flexibility to add various alloying elements like **Nickel (Ni), Chromium (Cr), and Molybdenum (Mo)** to achieve the 90 ksi strength and tailor properties for specific applications.
This allows for customized **welding wire formulations** beyond rigid prescriptive standards.

Question 3: What types of steels are best suited for welding with ER90S-G?

ER90S-G is ideal for welding low-alloy, high-strength steels, including various quenched and tempered steels and certain fine-grained structural steels.
It's selected when the weld needs to match or exceed the strength and toughness of advanced base materials.
This makes it a go-to for demanding **heavy fabrication** and structural projects.

Question 4: What specific mechanical properties are often enhanced in ER90S-G wires?

Beyond high tensile strength, ER90S-G wires are often engineered for enhanced **impact toughness**, even at very low temperatures (e.g., -30°C or -40°C), and improved creep resistance for elevated temperature service.
Manufacturers achieve these by carefully selecting and balancing the alloying elements, ensuring the **weld metal performance** in critical environments.

Question 5: What shielding gases are typically recommended for ER90S-G?

For ER90S-G, common choices include Argon/CO2 mixtures (e.g., 75% Ar / 25% CO2, or 80% Ar / 20% CO2) for stable spray or pulsed spray transfer.
These blends generally provide a smoother arc and less spatter.
While 100% CO2 can be used for deeper penetration, mixed gases often offer superior **arc stability** and bead appearance, making them popular for high-quality work.

Question 6: How does the higher strength of ER90S-G affect welding procedures compared to mild steel wires?

The higher strength and alloy content of both the wire and the base metals it welds often necessitate more stringent **welding procedure specifications (WPS)**.
This typically includes requirements for preheating, controlled interpass temperatures, and sometimes post-weld heat treatment (PWHT) to prevent hydrogen-induced cracking and ensure optimal **weld integrity**.

Question 7: Is ER90S-G suitable for critical structural components like bridges?

Yes, ER90S-G is widely used in the construction of critical structural components, including bridges and high-rise buildings.
Its ability to deliver high-strength, tough welds that can withstand significant loads and environmental stresses is paramount for the long-term reliability and safety of such **major infrastructure projects**.

Question 8: Can ER90S-G be effectively used in automated or robotic welding systems?

Absolutely.
Manufacturers design ER90S-G wires with excellent wire feeding characteristics and stable arc performance, which are crucial for automated and robotic welding.
This allows for consistent high-quality welds, increased deposition rates, and improved overall efficiency in **high-volume production** environments.

Question 9: What role do alloying elements like Cr and Mo play in certain ER90S-G formulations?

Chromium (Cr) and Molybdenum (Mo) are often included in ER90S-G formulations to enhance specific properties.
Molybdenum typically improves **creep resistance** at elevated temperatures and contributes to overall strength.
Chromium enhances strength, toughness, and sometimes corrosion resistance.
Their presence allows the wire to perform in demanding high-temperature or high-stress applications.

Question 10: How does ER90S-G handle welding on contaminated surfaces?

While optimal results always come from clean base metals, the deoxidizer levels in ER90S-G vary by manufacturer's specific formulation.
Some formulations may offer improved tolerance for light mill scale or rust due to enhanced silicon and manganese content, though usually to a lesser extent than an ER70S-6 wire.
For critical **high-strength welds**, thorough surface preparation remains highly recommended.

Question 11: What are common challenges when welding with ER90S-G?

Challenges can include managing higher residual stresses due to the strength of the weld metal, increased susceptibility to hydrogen-induced cracking in susceptible base metals (necessitating strict hydrogen control), and the need for precise parameter control to maintain desired mechanical properties.
Careful attention to **welding metallurgy** and procedures is key.

Question 12: Is ER90S-G typically used for multi-pass welding applications?

Yes, ER90S-G is frequently used for multi-pass welding, especially on thick sections or when building up large weld volumes.
Its consistent mechanical properties across multiple passes are crucial for ensuring the integrity of the final weld.
Proper interpass temperature control is vital for success in **multi-pass welding** of high-strength steels.

Question 13: What distinguishes ER90S-G from specific classifications like ER90S-D2 or ER90S-B3?

ER90S-D2 and ER90S-B3 (under AWS A5.28) have precisely defined chemical compositions for specific alloying elements, like manganese-molybdenum for D2 or chromium-molybdenum for B3.
ER90S-G, conversely, is a general classification where the exact chemistry can vary, as long as it meets the 90 ksi strength.
This means a manufacturer's ER90S-G might perform similarly but with a proprietary **chemical balance**.
It's about flexibility versus strict definition.

Question 14: What kind of weld bead appearance can be expected with ER90S-G?

When welded with appropriate parameters and shielding gas, ER90S-G typically produces a smooth, consistent, and well-contoured weld bead.
Manufacturers optimize these wires for good wetting action and minimal spatter, which contributes to a clean finish and reduces the need for extensive post-weld grinding, enhancing overall **welding aesthetics**.

Question 15: Are there specific safety considerations for welding with ER90S-G due to its alloys?

While general welding safety applies, the presence of various alloying elements (Cr, Mo, Ni, etc.) in ER90S-G means that welding fumes might contain a broader range of metallic oxides.
Therefore, extra emphasis on robust ventilation and appropriate **fume extraction systems** is critical to protect welder health.
Always consult the Material Safety Data Sheet (MSDS) for specific fume content and safety precautions.

Question 16: What is the typical shelf life of ER90S-G welding wire?

When stored correctly in its original, sealed packaging in a dry, temperate environment, ER90S-G welding wire can have a very long, often indefinite, shelf life.
Protecting it from moisture, humidity, and corrosive atmospheres is crucial to prevent surface rust or degradation that could impact wire feeding and weld quality.
Proper **welding consumable storage** is paramount.

Question 17: How does ER90S-G contribute to the performance of heavy machinery?

In heavy machinery, ER90S-G contributes by enabling the fabrication of components from high-strength steels that can withstand immense loads, impacts, and fatigue.
Its superior strength and toughness ensure the structural integrity and longevity of critical parts like excavator arms, crane booms, and chassis, directly impacting the **equipment's reliability** and lifespan.

Question 18: Is post-weld heat treatment (PWHT) ever required for ER90S-G welds?

Yes, depending on the base material, thickness, and service requirements, **post-weld heat treatment (PWHT)** may be required for ER90S-G welds.
PWHT helps to temper the weld metal and heat-affected zone, reduce residual stresses, and improve toughness and ductility, particularly in highly restrained joints or for applications requiring specific material properties.
Follow relevant codes and standards strictly.

Question 19: What should a welder consider when switching from mild steel to ER90S-G?

Welders should anticipate a need for stricter control over parameters, potentially higher preheat temperatures, and a greater emphasis on cleanliness.
The arc characteristics and puddle fluidity might feel different due to the alloying elements.
Understanding the specific WPS and practicing on test pieces are crucial for a successful transition to **high-strength welding**.

Question 20: Where can I obtain precise technical data for a particular ER90S-G wire?

Due to the "G" classification's flexibility, it's essential to consult the specific product data sheet provided by the welding wire manufacturer (e.g., Lincoln Electric, Esab, Hobart, Voestalpine Böhler Welding).
These sheets will detail the exact chemical composition, comprehensive mechanical properties (including impact data), recommended shielding gases, and suggested welding parameters for their unique **ER90S-G formulation**.