Low Alloy & High Strength
ER90S-D2
ER90S-D2 welding wire is an AWS A5.28 low-alloy solid welding wire designed for high-strength carbon and low-alloy steel applications. With controlled Mn-Si-Mo chemistry and ER90-class weld-metal strength, it is suitable for piping, pressure equipment, construction machinery and heavy industrial fabrication. ER90S-D2 provides a practical option when higher weld-metal strength and reliable low-alloy welding performance are required.
ER90S-D2 Welding Wire
ER90S-D2 is an AWS A5.28 low-alloy solid welding wire for applications requiring 90 ksi-class weld-metal strength and controlled Mn-Mo alloy chemistry.
It is designed for welding compatible high-strength carbon and low-alloy steels, with applications including piping, pressure equipment, construction machinery and heavy industrial fabrication.
ER90S-D2 is part of the D2 low-alloy welding wire classification, making it different from ER90S-G and other manufacturer-defined G classifications.
ER90S-D2 Welding Wire — Key Specifications
Item | Specification |
|---|---|
AWS Classification | ER90S-D2 |
AWS Specification | AWS A5.28 / ASME SFA-5.28 |
Product Type | Solid Welding Wire / TIG Filler Rod |
Alloy System | Mn-Si-Mo low-alloy steel |
Strength Class | ER90 |
Tensile Strength | 620 MPa / 90 ksi min. |
Yield Strength | 540 MPa / 78 ksi min. |
Elongation | 17% min. |
Welding Processes | GMAW / GTAW, depending on product form |
Typical Applications | High-strength low-alloy steel, piping, pressure equipment, machinery |
Product Form | Spool / Rod |
Documentation | TDS / MTC / CoA |
The listed mechanical properties are minimum classification values; actual product results should be confirmed against the manufacturer's current technical documentation.
ER90S-D2 Chemical Composition
ER90S-D2 has a controlled low-alloy chemistry based on manganese, silicon and molybdenum.
Typical AWS classification limits include:
Element | Typical Range / Limit |
|---|---|
Carbon (C) | 0.07–0.12% |
Manganese (Mn) | 1.60–2.10% |
Silicon (Si) | 0.50–0.80% |
Molybdenum (Mo) | 0.40–0.60% |
Nickel (Ni) | 0.15% max. |
Sulfur (S) | 0.025% max. |
Phosphorus (P) | 0.025% max. |
Copper (Cu) | 0.50% max. |
Actual chemical composition should be checked against the specific ER90S-D2 product TDS and MTC. Manufacturer data also shows typical chemistry around 0.09% C, 1.8% Mn, 0.65% Si and 0.52% Mo.
What Is ER90S-D2 Used For?
ER90S-D2 is selected when the application requires an ER90-strength low-alloy weld metal with D2-type Mn-Si-Mo chemistry.
Typical applications include:
- High-strength low-alloy steel fabrication
- Piping and fittings
- Pressure vessels and pressure equipment
- Valves and flanges
- Construction machinery
- Heavy industrial equipment
- Structural components requiring higher-strength weld metal
Some commercial ER90S-D2 products are specifically marketed for pipelines, fittings, flanges, valves and pressure vessels. Application suitability should always be verified against the base material, service conditions and qualified welding procedure.
ER90S-D2 Mechanical Properties
The AWS ER90S-D2 classification provides the following minimum all-weld-metal mechanical properties:
Property | Minimum |
|---|---|
Tensile Strength | 620 MPa / 90 ksi |
Yield Strength | 540 MPa / 78 ksi |
Elongation | 17% |
Charpy V-Notch | 27 J / 20 ft·lbf at −29°C / −20°F |
The exact testing condition and shielding gas should be confirmed against the applicable AWS edition and manufacturer's product documentation.
ER90S-D2 Welding Process
GMAW / MIG
ER90S-D2 is commonly supplied as a solid wire for gas-shielded MIG/GMAW welding.
The appropriate shielding gas depends on the specific product and classification requirements. Follow the manufacturer's TDS and qualified WPS rather than applying a generic gas recommendation.
Important welding variables include:
- Wire diameter
- Shielding gas
- Welding current
- Arc voltage
- Wire-feed speed
- Travel speed
- Heat input
GTAW / TIG
Where supplied as TIG filler rod, ER90S-D2 can be used for controlled welding applications such as pipe root passes and precision fabrication.
Confirm product form and procedure qualification before ordering.
ER90S-D2 Welding Procedure Considerations
For high-strength low-alloy steel, consumable selection is only one part of weld quality.
The qualified WPS should establish the applicable:
Base Material → Preheat → Interpass Temperature → Heat Input → Welding Parameters → PWHT, if required
The correct procedure depends on:
- Base-material grade
- Material thickness
- Joint design
- Welding position
- Service temperature
- Applicable code
- Hydrogen-control requirements
- PWHT requirements
Do not use a generic preheat or PWHT value without checking the base-material specification and qualified WPS/PQR.
ER90S-D2 vs ER80S-D2
ER80S-D2 is the most direct comparison when selecting a D2-family welding wire.
| ER90S-D2 | ER80S-D2 |
|---|---|---|
Strength Class | ER90 | ER80 |
Tensile Strength | 620 MPa / 90 ksi min. | 550 MPa / 80 ksi min. |
Yield Strength | 540 MPa / 78 ksi min. | 470 MPa / 68 ksi min. |
Elongation | 17% min. | 17% min. |
Alloy Family | Mn-Si-Mo | Mn-Si-Mo |
Main Selection Factor | Higher weld-metal strength | ER80 strength requirement |
Both are D2 classifications, but ER90S-D2 should not automatically replace ER80S-D2. The required weld-metal strength, base material and qualified WPS/PQR should determine the selection.
ER90S-D2 vs ER90S-G
Both classifications are within the ER90 strength level, but their chemistry is different.
| ER90S-D2 | ER90S-G |
|---|---|---|
Classification | D2 | G |
Strength Class | ER90 | ER90 |
Chemistry | Controlled D2 chemistry | Manufacturer-defined within classification requirements |
Alloy System | Mn-Si-Mo | Product dependent |
Selection Focus | D2 chemistry + strength | Actual chemistry + strength + application |
Therefore, ER90S-D2 and ER90S-G should not be treated as interchangeable simply because both are ER90 classifications.
ER90S-D2 vs ER90S-B3
These two welding wires have the same nominal ER90 strength class but different alloy systems.
| ER90S-D2 | ER90S-B3 |
|---|---|---|
Strength Class | ER90 | ER90 |
Alloy System | Mn-Si-Mo | Cr-Mo |
Main Alloying Elements | Mn / Si / Mo | Cr / Mo |
Typical Application Focus | High-strength low-alloy steel | Cr-Mo steels |
Selection Basis | D2 chemistry + strength | Cr-Mo compatibility |
ER90S-D2 should not be selected as a substitute for ER90S-B3 solely because both are ER90 classifications.
For P22/T22 and other Cr-Mo applications, the consumable should match the required Cr-Mo weld-metal chemistry and qualified welding procedure.
How to Select ER90S-D2 Welding Wire
Before purchasing ER90S-D2, confirm these seven points:
1. Base Material
What exact steel grade will be welded?
2. Required Strength
Does the weld metal need an ER90 strength classification?
3. Toughness
Is Charpy impact performance required? At what temperature?
4. Welding Process
GMAW/MIG or GTAW/TIG?
5. Shielding Gas
Which gas is specified by the product TDS and WPS?
6. Heat Treatment
Are preheat, interpass control or PWHT required?
7. Certification
Are TDS, MTC, CoA, impact data or third-party inspection documents required?
This information helps determine whether ER90S-D2 is appropriate before quotation.
Diameter and Packaging
ER90S-D2 can be supplied in different wire diameters and packaging formats depending on product availability.
Common formats may include:
- MIG/GMAW spools
- TIG/GTAW rods
- Different wire diameters
- Standard industrial packaging
- Customized packaging for project requirements
Available sizes and packaging should be confirmed for the specific product.
For a quotation, provide:
AWS Classification + Diameter + Base Material + Welding Process + Shielding Gas + Application + Quantity
Technical Documentation
For industrial and project-based purchasing, GD WELD can provide technical documentation according to product availability and customer requirements.
Typical documents may include:
- Technical Data Sheet (TDS)
- Mill Test Certificate (MTC)
- Certificate of Analysis (CoA)
- Chemical composition
- Mechanical properties
- Impact-test data
- Certificate of Conformity
- Packaging information
For pressure equipment or code-controlled projects, confirm documentation requirements before ordering.
Frequently Asked Questions
What is ER90S-D2 welding wire?
ER90S-D2 is an AWS A5.28 low-alloy solid welding wire classification for ER90-strength weld metal with controlled Mn-Si-Mo chemistry.
What is ER90S-D2 used for?
It is used for compatible high-strength carbon and low-alloy steels, including selected piping, pressure equipment, machinery and heavy industrial applications.
What is the difference between ER80S-D2 and ER90S-D2?
Both are D2-family classifications, but ER90S-D2 provides the higher ER90 weld-metal strength level.
What are the mechanical properties of ER90S-D2?
The classification minimums include 620 MPa tensile strength, 540 MPa yield strength and 17% elongation.
Can ER90S-D2 replace ER80S-D2?
Not automatically. The required weld-metal strength and qualified welding procedure should support the selection.
Can ER90S-D2 replace ER90S-B3?
Not automatically. D2 and B3 use different alloy systems and are intended for different material/application requirements.
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