Low Alloy & High Strength
ER80S-Ni2
AWS A5.28 ER80S-Ni2 low-alloy welding wire with approximately 2% nickel for low-temperature and high-toughness steel applications, including LNG equipment, pipelines, storage tanks, pressure vessels and offshore structures. ER80S-Ni2 is a nickel-alloyed solid welding wire designed for compatible low-temperature steels where good weld-metal impact toughness is required at sub-zero temperatures. It is available for GMAW/MIG and GTAW/TIG applications, depending on product form and specification.
ER80S-Ni2 Welding Wire
ER80S-Ni2 is an AWS A5.28 nickel-alloyed solid welding wire for compatible low-alloy and nickel steels where weld-metal strength and low-temperature toughness are important.
With a controlled nickel content of 2.00–2.75%, ER80S-Ni2 is designed for applications requiring reliable weld-metal toughness at reduced temperatures. It is commonly considered for low-temperature piping, pressure vessels, storage equipment, offshore structures and other critical low-alloy steel fabrication.
The correct consumable should be selected according to the base material, design temperature, impact requirements and qualified WPS/PQR.
ER80S-Ni2 Product Overview
Item | Specification |
|---|---|
AWS Classification | ER80S-Ni2 |
AWS Specification | AWS A5.28 / ASME SFA-5.28 |
Product Type | Solid Welding Wire / TIG Filler Rod |
Alloy Family | Nickel-alloyed low-alloy steel |
Nickel Content | 2.00–2.75% |
Strength Classification | ER80 |
Main Application Focus | Low-temperature and high-toughness welding |
Welding Processes | GMAW/MIG, GTAW/TIG, according to product form |
Typical Applications | Piping, pressure vessels, storage tanks, offshore and industrial equipment |
Product Forms | Spool / Rod |
Documentation | TDS / MTC / CoA according to requirements |
AWS A5.28 identifies ER80S-Ni2 as part of the nickel-steel electrode and rod classifications, with Ni requirements of 2.00–2.75%.
ER80S-Ni2 Chemical Composition
The defining feature of ER80S-Ni2 is its controlled nickel-alloy chemistry.
Element | AWS Classification Requirement, wt.% |
|---|---|
Carbon (C) | 0.12 max. |
Manganese (Mn) | 1.25 max. |
Silicon (Si) | 0.40–0.80 |
Phosphorus (P) | 0.025 max. |
Sulfur (S) | 0.025 max. |
Nickel (Ni) | 2.00–2.75 |
Copper (Cu) | 0.35 max. |
These are classification limits rather than guaranteed batch chemistry. Actual composition should be verified against the supplied GD WELD TDS and MTC/CoA.
Why Nickel Matters
Nickel is the key alloying element that distinguishes the Ni2 classification.
For compatible low-alloy and nickel-steel applications, nickel-alloyed weld metal can provide useful toughness at reduced temperatures. This is why ER80S-Ni2 is relevant to projects where low-temperature impact performance is an important purchasing requirement.
ER80S-Ni2 Mechanical Properties
ER80S-Ni2 belongs to the ER80 strength classification.
Typical AWS minimum requirements include:
Property | Minimum Classification Requirement |
|---|---|
Tensile Strength | 550 MPa / 80 ksi |
Yield Strength | 470 MPa / 68 ksi |
Elongation | 24% |
Charpy V-Notch | 20 ft·lbf / 27 J at −50°F / −46°C, according to applicable classification requirements |
Actual weld-metal results can vary with welding process, shielding gas, heat input, base material and testing condition. Always use the applicable product TDS and qualified WPS/PQR for project acceptance.
Commercial ER80S-Ni2 products may report higher typical values; these should not be confused with AWS minimum classification requirements.
What Materials Is ER80S-Ni2 Used For?
ER80S-Ni2 is intended for compatible nickel steels and low-alloy steels where the required weld-metal chemistry and toughness are specified.
Potential applications include:
- 2.5% nickel steels
- Low-temperature service steels
- Low-alloy pressure equipment
- Piping and process equipment
- Storage tanks
- Offshore structures
- Heavy industrial equipment
- Low-temperature welded structures
ER80S-Ni2 is commonly associated with welding 2.5% nickel steels and applications requiring good toughness at reduced temperatures.
The exact base-material pairing must be confirmed against the applicable material specification and qualified welding procedure.
ER80S-Ni2 for Low-Temperature Welding
Low-temperature welding wire is one of the key application areas for ER80S-Ni2.
When welded equipment operates below normal ambient temperatures, weld-metal tensile strength alone is not enough for consumable selection. The project may also specify:
- Charpy impact toughness
- Minimum test temperature
- Minimum absorbed energy
- Weld-metal chemistry
- PWHT condition
- Applicable construction code
For this reason, ER80S-Ni2 can be considered where the welding procedure requires a nickel-alloyed ER80 consumable with specified low-temperature impact performance.
Before ordering, confirm:
Base Material + Minimum Design Temperature + Impact Requirement + AWS Classification + WPS/PQR
ER80S-Ni2 Impact Toughness
For low-temperature applications, Charpy V-notch testing may be a critical part of consumable qualification.
The required impact performance should be evaluated together with:
Test Temperature + Absorbed Energy + Welding Process + Heat Input + PWHT
Do not select ER80S-Ni2 solely because it contains approximately 2% nickel.
For critical applications, verify the actual impact-test results from the product documentation and confirm that the consumable is qualified for the intended application.
ER80S-Ni2 Welding Processes
GMAW / MIG
ER80S-Ni2 can be supplied as solid wire for GMAW/MIG applications, depending on the product specification.
Important variables include:
- Wire diameter
- Shielding gas
- Welding current
- Arc voltage
- Wire-feed speed
- Travel speed
- Heat input
Shielding gas and welding parameters should follow the manufacturer's TDS and qualified WPS rather than a generic recommendation.
Commercial ER80S-Ni2 products are available for gas-shielded welding applications, with specific gas and parameter recommendations varying by product.
GTAW / TIG
ER80S-Ni2 can also be supplied as TIG filler rod.
GTAW may be selected when the project requires controlled filler-metal deposition, such as:
- Pipe root passes
- Critical joints
- Precision fabrication
- Low-temperature pressure equipment
Product form and welding procedure should be confirmed before ordering.
ER80S-Ni2 Welding Procedure Considerations
The consumable is only one part of the welding procedure.
Depending on the base material and application, the qualified WPS may control:
Preheat → Interpass Temperature → Heat Input → Cooling → PWHT
Other important factors include:
- Base-material chemistry
- Material thickness
- Joint design
- Welding position
- Shielding gas
- Welding process
- Service temperature
- Applicable code
- Impact-test requirements
For low-temperature applications, the complete welding procedure should be qualified to demonstrate the required weld-metal properties.
ER80S-Ni2 vs ER80S-Ni1
Both are nickel-alloyed ER80 welding consumables, but their nickel classifications are different.
| ER80S-Ni2 | ER80S-Ni1 |
|---|---|---|
Classification | Ni2 | Ni1 |
Strength Class | ER80 | ER80 |
Nickel Range | 2.00–2.75% | 0.80–1.10% |
Alloy Family | Nickel steel | Nickel steel |
Main Selection Factor | Ni2 chemistry and toughness requirements | Ni1 chemistry and toughness requirements |
Typical Focus | Low-temperature / nickel-steel applications | Low-temperature / nickel-steel applications |
The choice should be based on the specified AWS classification, base material and qualified WPS/PQR—not simply on the amount of nickel.
ER80S-Ni2 vs ER80S-B2
These two classifications belong to different alloy families.
| ER80S-Ni2 | ER80S-B2 |
|---|---|---|
Alloy Family | Nickel steel | Cr-Mo steel |
Main Alloying Element | Nickel | Chromium + Molybdenum |
Typical Material Focus | Nickel / low-temperature steels | P11 / T11 and compatible Cr-Mo steels |
Main Service Focus | Low-temperature toughness | Elevated-temperature service |
Typical Applications | Low-temperature piping, vessels, tanks | Boiler, steam and Cr-Mo piping |
Low-temperature nickel-steel application → ER80S-Ni2
P11/T11 Cr-Mo application → ER80S-B2
The two classifications should not be treated as interchangeable.
ER80S-Ni2 vs ER90S-B3
ER80S-Ni2 and ER90S-B3 address different material and service requirements.
| ER80S-Ni2 | ER90S-B3 |
|---|---|---|
Strength Class | ER80 | ER90 |
Alloy Family | Nickel steel | Cr-Mo steel |
Main Alloying System | Ni | 2.25Cr-1Mo |
Typical Material Focus | Nickel / low-temperature steels | P22 / T22 and compatible Cr-Mo steels |
Main Service Focus | Low-temperature toughness | Elevated-temperature service |
Typical Applications | Low-temperature equipment | Boiler, refinery and power equipment |
ER80S-Ni2 should not be substituted for ER90S-B3 simply because both are low-alloy welding wires. The base material and service conditions determine the appropriate classification.
How to Choose ER80S-Ni2 Welding Wire
Before purchasing ER80S-Ni2, confirm the following:
1. Base Material
Identify the exact steel grade and material specification.
2. AWS Classification
Does the WPS or project specification require ER80S-Ni2?
3. Service Temperature
What is the minimum design or operating temperature?
4. Impact Requirement
What Charpy test temperature and minimum absorbed energy are required?
5. Welding Process
GMAW/MIG or GTAW/TIG?
6. Wire Diameter
Which diameter is specified by the qualified WPS?
7. PWHT
Is post-weld heat treatment required?
8. Documentation
Are MTC, CoA, impact-test data or third-party inspection documents required?
9. Packaging
Spool, TIG rod or project-specific packaging?
Providing these details allows the welding consumable to be matched to the actual project requirement.
ER80S-Ni2 Diameter and Packaging
ER80S-Ni2 can be supplied in different diameters and packaging formats depending on the welding process and product specification.
Possible forms include:
- MIG/GMAW spools
- TIG/GTAW rods
- Different wire diameters
- Standard industrial packaging
- Customized packaging for project requirements
Available sizes should be confirmed against the current product supply program.
For quotation, provide:
AWS Classification + Diameter + Welding Process + Packaging + Quantity
Quality and Technical Documentation
For industrial and project-based purchasing, available documentation may include:
- Technical Data Sheet (TDS)
- Mill Test Certificate (MTC)
- Certificate of Analysis (CoA)
- Chemical composition
- Mechanical properties
- Charpy impact-test data
- Certificate of Conformity
- Packaging information
- Project-specific documentation
For low-temperature or pressure-equipment applications, confirm documentation and impact-test requirements before ordering.
Frequently Asked Questions
What is ER80S-Ni2 welding wire?
ER80S-Ni2 is an AWS A5.28 nickel-alloyed solid welding wire classified for ER80-strength weld metal and Ni2 chemistry.
What does Ni2 mean in ER80S-Ni2?
Ni2 identifies the nickel-steel classification with a nickel range of 2.00–2.75% under AWS A5.28.
What is ER80S-Ni2 used for?
It is used for compatible nickel and low-alloy steels where weld-metal strength and low-temperature toughness are important, including selected piping, pressure vessels, storage equipment and offshore applications.
Is ER80S-Ni2 suitable for low-temperature service?
It can be suitable when the base material, required impact properties and qualified welding procedure support its use.
What is the difference between ER80S-Ni1 and ER80S-Ni2?
Both are ER80 nickel-alloyed classifications, but Ni1 and Ni2 have different nickel ranges and therefore should be selected according to the specified material and welding procedure.
Can ER80S-Ni2 replace ER80S-B2?
No automatic substitution should be assumed. ER80S-Ni2 is a nickel-steel classification, while ER80S-B2 is a Cr-Mo classification used for compatible Cr-Mo steels.
Does ER80S-Ni2 require PWHT?
PWHT depends on the base material, thickness, welding procedure and applicable code. Follow the qualified WPS/PQR.
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