Low Alloy & High Strength
ER100S-G
ER100S-G welding wire is an AWS A5.28 high-strength low-alloy solid welding wire classification for applications requiring ER100-strength weld metal and manufacturer-defined alloy chemistry. The G classification does not define one single fixed alloy chemistry, so the actual chemical composition, mechanical properties and application should be verified from the manufacturer's technical documentation and qualified welding procedure.
ER100S-G Welding Wire
ER100S-G is an AWS A5.28 high-strength low-alloy solid welding wire classification for applications requiring ER100-strength weld metal and controlled alloy chemistry.
Unlike specific alloy classifications such as ER90S-B3 or ER90S-B9, ER100S-G does not represent one fixed chemical composition. The actual alloy chemistry is manufacturer-defined within the applicable AWS requirements.
For this reason, selecting ER100S-G requires more than checking the AWS classification. Buyers should consider the base material, weld-metal chemistry, strength, toughness, welding process, heat treatment and WPS/PQR.
ER100S-G Specifications
Item | Details |
|---|---|
AWS Classification | ER100S-G |
AWS Specification | AWS A5.28 / ASME SFA-5.28 |
Product Type | Solid Welding Wire / TIG Filler Rod |
Strength Classification | ER100 |
Alloy System | Manufacturer-defined low-alloy chemistry |
Welding Processes | GMAW/MIG, GTAW/TIG |
Typical Applications | High-strength and low-alloy steel applications |
Product Form | Spool / Rod |
Documentation | TDS / MTC / CoA |
What Does ER100S-G Mean?
The ER100S-G designation can be understood as follows:
- ER — electrode or filler metal classification
- 100 — 100 ksi-class tensile-strength level
- S — solid wire
- G — general classification with manufacturer-defined alloy chemistry
The ER100 strength level makes this classification suitable for selected applications where higher-strength weld metal is required.
However, strength alone does not determine consumable compatibility.
A practical selection approach is:
Base Material → Weld-Metal Chemistry → Strength → Toughness → WPS/PQR
Why the G Classification Matters
The most important purchasing consideration for ER100S-G is that G does not identify one specific alloy system.
Specific classifications such as B3 or B9 are associated with defined alloy systems, while ER100S-G allows the manufacturer to establish the product chemistry within the applicable classification requirements.
Therefore, two ER100S-G welding wires from different manufacturers should not automatically be assumed to have identical chemistry or identical application recommendations.
Before approving a product, buyers should review:
TDS + Chemical Composition + Mechanical Properties + MTC/CoA + Welding Procedure
This is particularly important for engineered, pressure-equipment and other code-controlled applications.
Technical Characteristics of ER100S-G
Chemical Composition
ER100S-G does not have one universal chemical composition.
Depending on the manufacturer's product design, controlled alloying elements may include:
- Carbon
- Manganese
- Silicon
- Chromium
- Nickel
- Molybdenum
- Copper
The actual composition must be confirmed from the specific product's technical documentation.
For critical applications, use the batch-specific MTC/CoA rather than relying only on the ER100S-G designation.
Mechanical Properties
ER100S-G belongs to the ER100 strength classification.
Typical minimum classification requirements in the supplied product information include:
Property | Minimum |
|---|---|
Tensile Strength | 690 MPa / 100 ksi |
Yield Strength | 610 MPa / 88 ksi |
Elongation | 16% |
Actual mechanical properties may vary according to the product, welding process and test conditions.
Relevant variables include:
- Welding process
- Shielding gas
- Heat input
- Welding parameters
- PWHT
- Test temperature
- Weld-metal chemistry
For project qualification, always use the manufacturer's current TDS and the qualified WPS/PQR.
Where Is ER100S-G Welding Wire Used?
There is no single universal base material or application for every ER100S-G product.
Its suitability depends on the actual chemistry and mechanical properties of the selected wire.
Potential application areas include:
High-Strength Steel Fabrication
ER100S-G may be considered where the weld metal requires a higher strength level than conventional ER70, ER80 or ER90 consumables.
Heavy Industrial Equipment
Suitable products may be used for selected heavy machinery and industrial components where higher-strength weld metal is required.
Structural Steel
ER100S-G may be considered for high-strength structural fabrication when permitted by the applicable specification and welding procedure.
Pressure Equipment and Piping
For pressure equipment and piping, the actual chemistry, mechanical properties, impact requirements, heat treatment and applicable code must be verified before use.
ER100S-G Welding Processes
GMAW / MIG
ER100S-G can be supplied as solid welding wire for GMAW/MIG applications according to the product specification.
Important parameters include:
- Wire diameter
- Shielding gas
- Welding current
- Voltage
- Wire-feed speed
- Travel speed
- Heat input
Actual parameters should follow the qualified WPS.
GTAW / TIG
Depending on product form, ER100S-G may also be supplied as TIG filler rod.
GTAW/TIG can be considered for:
- Pipe root passes
- Precision welding
- Critical joints
- Controlled deposition
Welding Procedure Considerations
Because the G classification does not define one fixed alloy chemistry, the welding procedure should be developed around the actual product rather than the AWS designation alone.
Important controls may include:
Preheat → Interpass Temperature → Heat Input → Controlled Cooling → PWHT
Requirements depend on:
- Base material
- Material thickness
- Joint design
- Welding process
- Service conditions
- Applicable code
- WPS/PQR
For high-strength steels, controlling heat input and preheat/interpass temperature can be important for achieving the required weld-metal and heat-affected-zone properties.
ER100S-G vs Other Welding Wire Classifications
Classification | Strength Level | Chemistry | Typical Selection Focus |
|---|---|---|---|
ER80S-G | ER80 | Manufacturer-defined | ER80-strength applications |
ER90S-G | ER90 | Manufacturer-defined | High-strength applications |
ER100S-G | ER100 | Manufacturer-defined | Higher-strength applications |
ER110S-G | ER110 | Manufacturer-defined | Higher-strength requirements |
ER120S-G | ER120 | Manufacturer-defined | Very high-strength applications |
The higher strength classification of ER100S-G does not automatically make it interchangeable with another G-classification or a specific alloy classification.
ER100S-G vs ER90S-B3
| ER100S-G | ER90S-B3 |
|---|---|---|
Classification | G | B3 |
Strength | ER100 | ER90 |
Chemistry | Manufacturer-defined | Specific Cr-Mo system |
Typical Material | Product dependent | P22 / T22-related |
Main Focus | High-strength applications | Elevated-temperature Cr-Mo service |
ER100S-G should not be selected as a replacement for ER90S-B3 simply because it has a higher strength classification.
ER100S-G vs ER90S-B9
| ER100S-G | ER90S-B9 |
|---|---|---|
Classification | G | B9 |
Strength | ER100 | ER90 |
Chemistry | Manufacturer-defined | Specific Cr-Mo system |
Typical Material | Product dependent | P91 / T91-related |
Main Focus | Product dependent | High-temperature Cr-Mo service |
For P91/T91-related applications, the consumable must satisfy the required Cr-Mo chemistry, mechanical properties, heat-treatment and qualification requirements.
Can ER100S-G Replace Another Welding Wire?
Not automatically.
A substitution should be evaluated against:
- Base material
- Required weld-metal strength
- Chemical composition
- Toughness
- Ductility
- Service conditions
- Welding procedure
- Applicable code
- Customer specification
A higher-strength classification does not by itself establish technical equivalence.
If a project specifies a particular alloy classification, the proposed alternative should be reviewed and qualified for the intended application.
How to Select the Correct ER100S-G Welding Wire
Before purchasing, confirm these key points:
1. Base Material
What steel grade is being welded?
2. Required Strength
What minimum weld-metal strength is required?
3. Product Chemistry
Which alloying elements are present in the actual ER100S-G product?
4. Toughness Requirements
Are Charpy impact properties required, and at what test temperature?
5. Service Conditions
What are the operating temperature and loading conditions?
6. Welding Process
Will the wire be used for GMAW/MIG or GTAW/TIG?
7. Heat Treatment
Are preheating, controlled cooling or PWHT required?
8. Applicable Code
Which AWS, ASME, EN or project specification applies?
9. WPS/PQR
Has the selected consumable been qualified for the intended application?
10. Certification
Are MTC, CoA, impact-test reports or third-party inspection required?
Diameter and Packaging
ER100S-G can be supplied in different wire diameters and packaging formats according to product availability and customer requirements.
Possible formats include:
- MIG/GMAW spools
- TIG/GTAW rods
- Different wire diameters
- Standard packaging
- Customized packaging
For quotation, provide:
AWS Classification + Diameter + Base Material + Welding Process + Application + Quantity
Technical Documents for ER100S-G
For project and material approval, buyers may request:
- Technical Data Sheet (TDS)
- Mill Test Certificate (MTC)
- Certificate of Analysis (CoA)
- Chemical composition
- Mechanical properties
- Impact test data
- Certificate of Conformity
- Packaging information
- Project-specific documentation
Because ER100S-G does not identify one fixed alloy chemistry, technical documentation is particularly important when material compatibility and qualification are critical.
Frequently Asked Questions
What is ER100S-G welding wire?
ER100S-G is an AWS A5.28 high-strength low-alloy solid welding wire classification with an ER100 strength level and manufacturer-defined alloy chemistry.
What does G mean in ER100S-G?
The G designation indicates a general classification where the alloy chemistry is not defined as one specific standardized alloy system in the same way as classifications such as B3 or B9.
Is ER100S-G a high-strength welding wire?
Yes. ER100S-G belongs to the ER100 strength classification, with a tensile-strength level of approximately 100 ksi.
What is ER100S-G used for?
Its application depends on the actual product chemistry and qualified welding procedure. Potential applications include selected high-strength low-alloy steel, industrial equipment, structural and pressure-equipment applications.
What is the difference between ER100S-G and ER90S-G?
Both are G-classification solid wires, but ER100S-G has the higher strength classification: approximately 100 ksi versus 90 ksi.
Can ER100S-G replace ER90S-G?
Not automatically. Base material, weld-metal requirements, toughness, welding procedure and applicable code must support the substitution.
Can ER100S-G be used for P91?
Do not assume it is suitable. P91 applications require consumables that meet the specific alloy, mechanical, heat-treatment and qualification requirements of the applicable welding procedure.
Can ER100S-G replace ER90S-B9?
Not automatically. B9 is a specific Cr-Mo classification, while G represents a manufacturer-defined chemistry classification.
What welding processes can use ER100S-G?
Depending on product form, ER100S-G may be supplied for GMAW/MIG and GTAW/TIG applications.
Does ER100S-G require PWHT?
PWHT depends on the base material, thickness, welding procedure and applicable code. Follow the qualified WPS/PQR.
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